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WEDM of AA6061: an insight investigation of axial and lateral dimensional errors

ABSTRACT Geometrical machining errors in terms of overcut and/or undercut are the inherent problems associated with wire-cut electric discharge machining (EDM) process. Such errors are ultimately transformed into compromised dimensional accuracy of the machined part. The magnitude of the said errors is presumed the same in both the cutting orientation of work part. However, practically there exists variations along both the cutting orientations, i.e. axial and lateral. Moreover, not only the lateral and axial dimensions are different from the designed dimensions but also a noticeable difference in errors magnitude is observed along both the cutting directions. Variation in kerf along different edges of the machined profile also plays a pivotal role in error amplification. Such difference in geometrical dimensions seriously matters in high-precision applications. Therefore, the present research examines the impact of seven control parameters for minimizing the magnitude of kerf width, axial and lateral dimensional errors. Al-alloy 6061 is taken as a substrate because of its wide use in precision-oriented applications. Parametric effects are thoroughly analyzed through statistical tests and SEM-based analysis. Results revealed that the use of optimal settings yields a reduction of 13.5%, 49%, and 27% in the magnitudes of kerf width, axial, and lateral dimensional errors, respectively.