An analysis and optimisation of the geometrical inaccuracy due to wire lag phenomenon in WEDM

An extensive study of the wire lag phenomenon in Wire-cut Electrical Discharge Machining (WEDM) has been carried out and the trend of variation of the geometrical inaccuracy caused due to wire lag with various machine control parameters has been established in this paper. In an extremely complicated machining process like Wire-cut EDM, which is governed by as many as ten control factors, it is very difficult to select the best parametric combination for a particular situation arising out of customer requirements. In the present research study, all the machine control parameters are considered simultaneously for the machining operation which comprised a rough cut followed by a trim cut. The objective of the study has been to carry out an experimental investigation based on the Taguchi method involving thirteen control factors with three levels for an orthogonal array L₂₇ (3¹³). The main influencing factors are determined for given machining criteria, such as: average cutting speed, surface finish characteristic and geometrical inaccuracy caused due to wire lag. Also, the optimum parametric settings for different machining situations have been found out and reported in the paper.