Parametric Effect on Wire Breakage Frequency and Surface Topography in WEDM of Pure Titanium

Wire electrical discharge machining (WEDM) is a non-traditional machining technique that is able to produce complicated and 3-D shapes through difficult machine metals without using high cost grinding or expensive formed tools. Wire electrical discharge machine should satisfy performance demands such as: high-speed cutting, resistant against wire rupture and accurate machining to improve the productivity and to achieve high quality in machining work pieces. Many factors have effect on the process of WEDM (cutting speed and work piece precision) including electrical parameters and electrode. But wire breakage frequency in the WEDM process decreases the productivity and quality of machined surface. This paper describes the effect of six input parameters i.e. Ton, Toff, Ip, SV, WF and WT on wire breakage frequency and the surface integrity of wear out wire during machining of pure titanium. An optimum range of input parameters has been selected for carrying out further research to develop the empirical models for WEDM of pure titanium.