Page 20 - 2020

Ph.D.
(Engineering & Technology)
DESIGN AND DEVELOPMENT OF CYLINDRICAL
WIRE CUT ELECTRICAL DISCHARGE MACHINE.

Ph.D. Scholar : Patel Harshadkumar Chaturbhai
Research Supervisor : Dr. Dhaval M. Patel

Regi. No.: 14146051006
Abstract :
The wire electrical discharge machine (EDM) was developed for cutting intricate profiles.
In modern edge, Wire EDM can be applied for turning on macro to micro parts, higher
length diameter ratio parts and difficult machining materials. From exhaustive literature
review, the use of presented CWEDM for cylindrical applications has comparatively less
material removal rate, high surface roughness and also high power consumption due to
the lack of synchronize rotary control method.

Through this research, to developed precise and dedicated CWEDM with design
indigenous synchronize rotary motion control because of required to use of dedicated
material-removing algorithms based on actual material removing, dedicated pulse
generation system and table motion control for machining of cylindrical parts. Developed
CWEDM focuses on synchronization between two new parameters; first is ‘degree of
motion of workpiece’ between 0.3° to 3° and the second is ‘Y-infeed after one revolution’
between 30-100 µm instead of ‘rotational speed of workpiece(r/min)’ and ‘linear feed
speed (mm/min)’ with a vision to improve performance parameters of rotational parts.

To investigate the material removal rate (MRR) and surface roughness (SR) effects for
widely used GCr15 Material by three different experiments.

The experiment-1 using time-dependent rotary motion control was performed to
investigate the relationship between Peak current (Ip), Spindle rotation (RPM), Infeed on
MRR. The results of the experiment show that the maximum value of MRR can achieve a
maximum of 4.2 mm3/min when the Ip, RPM and Infeed was 3 Amp, 60 r/min and 90 μm
respectively using time-dependent rotary control. If variable parameters like Ip, RPM and
Infeed are increase then the MRR is increased. Ip parameter is the most significant factor.

The experiment-2 is a comparison between time-dependent rotary control and developed
synchronized rotary motion control. The experimental results state that uniform SR is
3.322 to 3.562 µm achieved in case of developed synchronized rotary motion control
whereas time-dependent rotary control results show variation between 3.206 to 6.108
µm. In synchronized rotary motion control, improvement in MRR is 16.22% and reduction
in SR is 32.00% as compared to a time-dependent rotary control. Hence, the cylindrical
cutting decreases the undulating effect on the surface in developed CWEDM. The ‘degree
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