Özet:

The trim cut process in wire electrical discharge machining (WEDM) is considered as a possible solution to improve surface properties and geometric accuracy by removing a small amount of chip from the surface obtained after main cut process. In this work, the effects of cutting parameters on the mean surface roughness (Ra), quadratic mean roughness (Rq) and maximum roughness (Rz) criteria formed during the cutting of SAE 1080 carbon steel on the WEDM machine were investigated. Control factors were determined as the machine variables pulse duration (Ton), table feed speed (TS) and pulse interval (Toff). Experiments were performed based on the Taguchi L9 orthogonal sequence. Analysis of variance (ANOVA) was applied to define the impact levels of control factors on the Ra, Rq and Rz roughness criteria. Additionally, parameter optimization was performed using the “smallest is best” approach for main cutting and final cutting applications. Based on the ANOVA outcomes, it was detected that the most influence cutting parameter on the considered surface roughness criteria was the pulse duration in the main cut and trim cut. As a result of the study, it was seen that an average improvement of 21.5%, 10.5% and 12.5% was achieved for Ra, Rq and Rz, respectively, in the trim cut process compared to the main cut process.

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