The Machinability of Different Albromet W130 Plates Thicknesses by WEDM to the Required Surface Roughness Value

Abstract

Wire Electrical Discharge Machining (WEDM) technology represents an unconventional but vital manufacturing technology in many different industrial branches. The automotive industry and its many significant requirements bring the need to manufacture inserts and mould segments for plastic injections from Albromet W130 material, with a required roughness, Ra, from 4.5 to 5 mu m so that subsequent profile etching can be eliminated. A planned experiment of 60 rounds was carried out to discover the optimal machining parameters, namely, the pulse-off time, gap voltage, discharge current, pulse-on time, and wire speed in order for the thickness of 10 to 100 mm (after 10 mm) to demonstrate the required roughness. The goal was to evaluate the surface roughness, maximise the cutting speed, and manufacture it without surface or subsurface defects. The evaluation of the planned experiment led to the establishment of optimised WEDM machining parameters with which thicknesses of 10-100 mm will always be produced with the required roughness, Ra, from 4.5 to 5 mu m and with the highest possible cutting speed. It was also proven that the machining does not lead to surface or subsurface defects, and thus, the service life of the manufactured parts will not be affected.

Wire Electrical Discharge Machining (WEDM) technology represents an unconventional but vital manufacturing technology in many different industrial branches. The automotive industry and its many significant requirements bring the need to manufacture inserts and mould segments for plastic injections from Albromet W130 material, with a required roughness, Ra, from 4.5 to 5 mu m so that subsequent profile etching can be eliminated. A planned experiment of 60 rounds was carried out to discover the optimal machining parameters, namely, the pulse-off time, gap voltage, discharge current, pulse-on time, and wire speed in order for the thickness of 10 to 100 mm (after 10 mm) to demonstrate the required roughness. The goal was to evaluate the surface roughness, maximise the cutting speed, and manufacture it without surface or subsurface defects. The evaluation of the planned experiment led to the establishment of optimised WEDM machining parameters with which thicknesses of 10-100 mm will always be produced with the required roughness, Ra, from 4.5 to 5 mu m and with the highest possible cutting speed. It was also proven that the machining does not lead to surface or subsurface defects, and thus, the service life of the manufactured parts will not be affected.