Optimal Machine Parameters to Maximize the Accuracy of Producing Aluminum Dovetails Using WEDM

Dovetail joints are one of the strongest joining methods used to connect two perpendicular components together. Dovetail joints are predominantly used in wooden components but can also be found in other non-wood components and products such as lathes, turbine blades, clock gears, and large 3D printed components. The manufacturing of these joints have largely been done by CNC milling machines that use specialized tools. The objective of this study was to determine the optimal machine parameters to produce a dovetail joint in Aluminum 7075-T6 plate with the highest accuracy as possible using a WEDM process. The experimental results were analyzed through ANOVA and the optimal results were presented. Further work is also discussed to incorporate the manufacturing time into the model.