A Modeling Study on Surface Roughness of Spinneret Mold Sections Machined By WEDM

Abstract

The Wire Electrical Discharge Machining (Wire EDM) is widely used in the cutting of Bulk Continuous Filament (BCF) spinneret molds. Because of the low surface roughness of the spinneret molds obtained by the Wire EDM method, it ensures that the polypropylene material has a steady flow, volume and cross-sectional shape. Since the yarn extruded from the sections on the BCF acquire a number of physical and visual properties surface roughness of these molds have a great of importance. In this context, a new model was developed to predict the surface quality of spinneret mold sections, AISI 431 martensitic stainless steel, machined using Wire EDM by Analysis of variance (ANOVA). Machining parameters such as voltage, current, pulse time and wire feed rate were used as independent input variables and surface roughness was used as dependent output parameters. Contribution of input variables into the output variable determined by means of analysis of variance. Developed mathematical model estimations have been found to be in good agreement with the measured ones. The parameters with the most effect on surface roughness are listed as voltage, current, pulse, and feed, respectively. It is predicted that the steel used in spinneret mold can be machined more economically and practically by using the empirical formula obtained from this study.