Investigation on the effect of corner error in WEDM taper cutting process of Ti–6Al–4V

Wire Electrical Discharge Machining (WEDM) is a non-conventional manufacturing method known for producing high-quality surface finishes and relies on the condition that materials conduct electricity. However, corner inaccuracies arise in workpieces during corner cuts with this method. This study aims to investigate corner inaccuracies using a novel approach involving oblique cutting and considering parameters such as wire tension (WT), corner angle, taper ratio, nozzle gap, and dielectric flow rate (LQ). The lower and upper corners resulting from taper cutting are analyzed separately. Initially, the parameters were determined, and the experimental design was established using the Taguchi method. Subsequently, the Coordinate Measuring Machine (CMM) was employed to determine the point positions of the specimens. A unique software-based method was then utilized to analyze the obtained point positions, revealing deficiencies in the expected corner areas and exposing errors. Ultimately, the analysis of the results was conducted employing the ANOVA method, offering insights into the verification and outcomes of the conducted experiments. The study concludes that, when examining corner inaccuracies, the most influential parameters are wire tension and dielectric flow rate for both lower and upper corners in taper cutting.