2.1 Selection of wire electrode and work piece

A chrome coated cylindrical pure copper wire electrode having 0.25 mm in diameter and high tensile strength were selected for conducting machining operation on 18 mm diameter of D2 steel rod to cut 5 mm thickness of disk using Electronica Maxicut, WEDM process. It is very clear that D2 is hard die steel and conducting material with high carbon and chromium content (Table 1).

The experiment has carried out on Wire Electrical Discharge Machine, model ELECTRONICA-MAXICUT, SLNO -250, (F:09:0002:01) having the facilities to hold the work piece within the place provided by the help of conductive fixture, so that they can complete the circuit between electrode and work piece. The spark is created depending upon gap voltage applied between the conductive work piece, electrode, and machining performance influence the major independent process parameter which selected for experiment as characteristics of screening test.


Table 1. Metallurgical component analysis: D2 steel.

Optimization of Surface Roughness of D2 Steels in WEDM using ANN Technique DOI: http://dx.doi.org/10.5772/intechopen.81816

Figure 1. D2 steel machining using WEDM process.

as unique adaptation of the conventional EDM, which used an electrode to create the sparking within kerfs [11]. However, WEDM utilizes a continuously traveling chromium coated copper wire electrode ranging diameter 0.05–0.35 mm, which is capable to achieve very good sharpness of edge [4]. Very high temperature ranging 8000–10,000°C creates within the kerfs gap during machining, so that material removal may takes place by not only melting but directly vaporizations also. WEDM is used for the high precision machining to all type of electrically conductive metallic alloys, tool and die, graphite, and few ceramic and composite materials of any hardness which cannot be machined easily by conventional machining

Manufacturing processes (WEDM) has been chosen depending on the material characteristics and the type of responses required to be evaluating. The present study aimed to optimization of responses i.e. surface roughness with corresponding MRR of D2 steel by conducting 80 rows of experimental data using frictional

layered BPANN architecture has been used for modeling, where independent process variables are Vg, Fr Ton, Toff, Wf and Wt to get the précised and optimized values of responses Ra [6, 8, 10]. Best model S2 has been found on the basis of

The response (SR) is expressed as the irregularities of material resulted from various machining operations. It is represented as 'Ra'symbol and used to be called

The optimum process parameters are much essential to achieve better surface finish with adequate material removal rate (MRR) or shrink of total machining time; lot of research attempts has been reported for modeling and investigation of WEDM process parameters [7], but sum of root mean square error (SRMSE) approach have been used to optimize the process parameters by taking 55 rows of

A chrome coated cylindrical pure copper wire electrode having 0.25 mm in diameter and high tensile strength were selected for conducting machining operation on 18 mm diameter of D2 steel rod to cut 5 mm thickness of disk using Electronica Maxicut, WEDM process. It is very clear that D2 is hard die steel and

The experiment has carried out on Wire Electrical Discharge Machine, model ELECTRONICA-MAXICUT, SLNO -250, (F:09:0002:01) having the facilities to hold the work piece within the place provided by the help of conductive fixture, so that they can complete the circuit between electrode and work piece. The spark is created depending upon gap voltage applied between the conductive work piece, electrode, and machining performance influence the major independent process parameter which selected for experiment as characteristics of screening test.

C SI Cr Mo V HRC Conductivity 1.50% 0.30% 12.00% 0.80% 0.90% 56 22 (W/mk)

conducting material with high carbon and chromium content (Table 1).

center line arithmetic average roughness for the sampling length [2].

) design of experiment of five different set at three levels [3]. Four

) between observed and predicted responses (SR) [12].

methods [1, 5].

Applied Surface Science

factorial (26–<sup>2</sup>

training data [9].

Table 1.

112

Metallurgical component analysis: D2 steel.

2. Experimental setup

2.1 Selection of wire electrode and work piece

correlation coefficient (R<sup>2</sup>

Commercials grade of deionized water (density = 832 kg/m<sup>3</sup> ) was used as dielectric fluid. 18 mm cylindrical rod of D2 steel was used as the work piece with negative polarity and the power supply has the provision to connect the 0.25 mm chromium coated pure copper tool electrode with positive polarity so that the material removal may takes place by influence of heat generated within kerfs due to applied voltage within it (Figure 1).

The surface roughness Ra of the processed material have been measured precisely by using Surftest SJ-210 tester having center line average value (CLA), where least count of the equipment is 0.001 μm for the travel length of 0.85 mm (Figure 2).
