The 3D Taper Profile Machining of Superalloys and Composites Using WEDM: A Review

Abstract

Wire electric discharge machine (WEDM) is a process used popularly in microsystems, tool and die industries, medicine, transportation, and spacecrafts to create intricate portions with high dimensional accuracy and surface finish. It is employed to process superalloys and materials made of composites which are conductive and strong materials. From the literature, an analysis of the WEDM process on different materials revealed that there were many variables involved and that each process parameter influences the different response variables. The removal process of a spark discharge for an inclined angle during the cutting of 3D profiles has different applications. Also, types of dielectric fluid, and the influence of wire material, diameter and pressure, wire tension, feed, Ton, Toff, current, and voltage on machining characteristics—like kerf, MRR, wire wear, surface finish and its characteristics, dimensional deviations, and corner errors—and on a variety of materials like Inconel, nickel, titanium, WC, steels, and other superalloys and composites (MMCs and CMCs) during taper WEDM were reviewed.

Keywords

• three-dimensional profile machining
• superalloys and composites
• process parameter and responses