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Surface roughness and surface topography evaluation of Al 6065-T6 alloy using wire electro-discharge machining (wire EDM)

ABSTRACT Wire electro-discharge machining (EDM) is the thermo-electrical non-conventional machining process which is used to cut intricate components with the desired accuracy. The surface integrity of a wire EDM surface is not only strongly influenced by its process parameters but also with the number of finish cuts and wire offsets. In the present study, the evolution of the surface quality of the Al 6065-T6 alloy using brass coated (φ0.25 mm) wire with multiple trim cutting has been comprehensively studied. For the improvement of the surface quality in the machining zone, two successive finished cuts have been considered for the machining. In addition to this, two different wire-offset values of 70 µm and 120 µm have been considered, while other process parameters remain constant. The average roughness value of the rough cut surface is over 2.5 µm, whereas it tends to be 1.0 µm after the finish trim cutting operation. Compared to the rough cutting operation to the finish trim cutting, micro-notches and scratch craters are also visualised on the machined surface.