An experimental investigation on surface integrity and wire wear in rough and trim cut modes of WEDM for hybrid composite

Purpose The purpose of this paper is to investigate the surface integrity features, including surface roughness (SR), recast layer (RL), material migration, topography and wire wear pattern in rough and trim-cut wire electric discharge machine (WEDM) of hybrid composite (Al6061-90%/SiC-2.5%/TiB 2 -7.5%). Design/methodology/approach Effects of four important factors, namely, rough-cut history (RCH), pulse on time (T on ), peak current (IP) and wire offset (WO) have been assessed on the responses of interest for trim-cut WEDM. Box–Behnken design (RSM) was used to formulate the experimentation plan. Quantitative indices of surface integrity, namely, SR and RL, and selected samples have been investigated for qualitative analysis, namely, surface topography, material migration and wire wear pattern. Findings T on and IP are found to be most significant, whereas RCH and WO are found insignificant for SR. T on and WO were found to be the most significant factors affecting RL. After trim cut, an RL of thickness 8.26 µm is observed if the initial rough cut has been accomplished at high discharge energy setting. Whereas the best value of RL thickness, i.e. 5.36 µm, can be realized with low level of RCH. A significant decrease in the presence of foreign materials is recorded, indicating its strong correlation with the discharge energy used during machining. Originality/value Investigation on surface integrity features for machining of hybrid composite through rough and trim-cut WEDM has been reported by only a limited number of researchers in the past. This study is attempted at fulfilling few vital gaps by addressing the issues such as evaluation of the efficacy of trim cutting under different discharge energy conditions (using RCH), analysis of wire wear pattern in both rough and trim-cut modes and investigation of the wire breakage phenomenon during machining.