Analysis of Residual Stress on Commercially Pure Titanium Using Molybdenum Wire Machined on Reciprocated Travelling WEDM

Wirecut Electrical Discharge Machining (WEDM) is a cost-effective and productive method of cutting electrically conductive hard materials. WEDM has the added benefit of being more accurate when it comes to manufacturing component forms. In this research, the performance of reciprocated WEDM (RWEDM) on a titanium grade 2 alloy with a molybdenum wire electrode is evaluated by measuring the residual stresses present on the machined part for different conditions. Observations indicate that considerable residual stresses are seen in the specimen as watched from the X-ray diffraction test through measuring the residual stress, shear stress, D-spacing, full width at half maximum height, intensity, and breadth of stresses. Observations show that when feed rate of wire electrode in RWEDM and flow rate of dielectric is higher and higher variable frequency and higher current, residual stress tends to rise due to higher generation of spark density, which correspondingly removes higher quantity of material from the workpiece