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Process parameters selection is a critical task in wire electro-discharge machining (WEDM). The parameter settings would vary when a material to be machined is changed. In the present study, experimental investigation has been carried out for appropriate selection of process parameters in WEDM of Al 7075. It has been perceived that pulse on time (T on ), arc on time (A on ) pulse off time (T off ), arc off time (A off ), servo sensitivity (S c ), wire tension (W t ) and servo voltage (S v ) are the major influencing factors on machining speed (V c ), corner error (C e ) and surface roughness (R a ) for this alloy. It is also observed that selected seven process parameters are essential for effective machining of Al 7075 alloy. Finally, three-dimensional (3D) surface topography has been analysed to determine the characteristics of the machined surface.

Experimental investigation of process parameters in WEDM of Al 7075 alloy