Analysis the impact of WEDM parameters on surface microstructure using response surface methodology

Wire electrical discharge machining (WEDM) extensively used, mostly in machining of conductive materials by using precisely controlled sparks that occur between a very thin wire and a workpiece in the presence of a dielectric fluid. This study deals with Surface Roughness (SR), White Layer Thickness (WLT) and Depth of Heat Affected Zone (HAZ) in WEDM by changing Pulse on Time (Ton), Wire Tension (Wt) and Pulse Current (Ip) with respect of previous changes. This process is done by using a rod of high speed steel (HSS) as a workpiece and tool of cutting is a wire of brass with diameter equal to 0.25mm. The magnitudes of Surface Roughness, White Layer Thickness and Depth of Heat Affected Zone values are analyzed by factorial analyses data. The gained results shows that the current was the most influential parameter on the heat affected zone and white layer thickness while the wire tension has incredible influence on the surface roughness.