International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 09 | Sep 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 374 Effect of Wire Cut EDM Parameters on Material Removal Rate Venkat Lalit Shukla 1 , Dr. S.K.S Yadav 2 1 Venkat Lalit Shukla M.Tech Student, HBTU, Department of Mechanical Engineering Kanpur U.P. India 2 Dr S.K.S Yadav Assistant Professor, HBTU, Department of Mechanical Engineering Kanpur U.P. India ------------------------------------------------------------------------***----------------------------------------------------------------------- Abstract: Wire cut EDM is an advance fabrication process of contouring intricate shapes from bulk material. Wire EDM provides high surface finish with hard to cut new materials. The existing works deals with the optimization of process parameters while machining Titanium Alloy (6Al-4V) on Wire cut EDM. Titanium alloy is used in dental implant and other surgeries related to bones due to its excellent biocompatibility. Wire EDM an unconventional way of non contact machining is very useful to fabricate miniature size components. In order to predefine the values of parameters which have dominance over output parameter .the impact of input and output parameters is found with the help of MINITAB software Input parameters considered were Peak current, Pulse on time, Pulse off time and Wire speed and output Parameter is Material removal rate. Keywords -Wire EDM, pulse on time (TON) , pulse off time (TOFF) and Material removal rate(MRR) MINITAB. 1. Introduction Wire was developed in 1960s to cut tool dies, extrusion dies of good accuracy and tolerance. Wire EDM is an unusual non contact process for metal removal. In Wire Cut EDM the metal is cut by thermal heat of the spark In this system wire acts as electrode which moves uninterruptly through the workpiece. Generally wire diameter ranges from 0.25-0.3 mm. WEDM provides effective solution to fabrication new materials having high strength at elevated temperature. The materials of space application such as titanium, cemented carbides, conduct ceramics can be cut very easily with the help of wire EDM .This process has good capability to cut intricate shapes and sizes with a very low value of surface roughness. The mechanism of material removal is formation of plasma channel between the wire electrode and the workpiece formed due to the dielectric breakdown of the dielectric. As the interelectrode gap reduces to about 0.2mm spark occurs and a high temperature of about 8000-10,000  C. Huge amount temperature and pressure causes melting of metal. The debris is carried away by the dielectric fluid (deionised water). The wire electrode also is set in motion to ensure that the wire rupture does not occur. The path of wire is operated by CNC controller in manner as shape required to be cut. The wire is continuously changed with every time spark occurring on fresh piece of wire. The dielectric fluid used wire EDM is deionised water. Wire EDM machine consists of power supply system, dielectric flow system, wire drive system and positioning system. Besides the common factors Tension of wire is an significant parameter in material removal If the wire tension is high enough the wire stays straight otherwise wire drags behind. This helps to keep the wire free from vibration. It is because if there is improper tension, it will produce vibration in the wire, which will further lead to in accuracy of the process. The wire is kept intact in one position with help of rolls. Nihat Tosun et.al [1] investigated on the effect of machining parameters on the kerf width and material removal rate (MRR) in wire electrical discharge machining (WEDM) operations. The experiments were conducted under varying pulse time, circuit voltage, wire travel speed and dielectric flushing pressure. Hewidy et al [2] developed mathematical models to find interrelationship among various WEDM machining parameters peak current, duty factor, wire tension and dielectric pressure with metal removal rate. Mahapatra [3] studied the relationships between various control factors and responses like MRR, SF and kerf by means of nonlinear regression analysis, resulting in a valid mathematical model.Singh H. et.al [4] investigated the effect of different process parameters of WEDM on material removal rate. Different process parameters such as pulse on time TON, pulse off time, gap voltage, peak current, wire feed rate and wire tension were taken into account. Rao M.S. et.al [5] reviewed the impact of Wire EDM process parameters on output parameters and the various optimization methods applied by the researchers and outlined the future trends in WEDM research. Sivakiran S. et.al [4] studied the effect