Experimental investigation of the effects of applying external alternating magnetic field around gap distance in wire electrical discharge machining of WC-Co, ISO K20

Tungsten carbide (WC) is a unique material in terms of high hardness, melting temperature, thermal degradation, and wear and chemical resistance. This hard material is mainly used in machining industries as tools. The machining of WC is difficult using traditional methods, due to its high hardness, so the modern machining methods such as wire electrical discharge machining (WEDM) are used. In this research, external alternating magnetic field assisted WEDM process was used for machining tungsten carbide cobalt (WC-Co) ISO K20 as workpiece and the effects of pulse on time, wire offset from the workpiece, and the intensity of applied magnetic field on material removal rate, machined surface roughness, and generated micro-cracks density on machined surface were investigated. Analysis of variance was also performed in order to study the effects of inputs on outputs, statistically. The obtained results indicated an increase in material removal rate (55.6% averagely), and a reduction in generated micro-cracks density on machined surface (58% averagely) by application of an external alternating magnetic field with an intensity of 12.088 G in WEDM process, in machining of WC-Co ISO K20. Of course, material removal rate is decreased and micro-cracks density of machined surface is increased by application of an external alternating magnetic field with an intensity of 15.104 G.