Review on Effects of Process Parameters in Wire Cut EDM and Wire Electrode Development (original) (raw)

Wire cut Electrical Discharge Machining (WEDM) is a non-traditional machining process which is based on thermoelectric energy between the workpiece and an electrode. The increase in the demand of higher surface finish and increased material removal rate requires newer and better techniques which are more efficient. Wire Electrical Discharge Machining is one such type of process which can which is used to manufacture geometrically intricate shapes with great accuracy and good surface finish that are difficult to machine with the help of conventional machining processes. It works on the principle of spark erosion and is capable of machining the materials irrespective of their hardness and toughness. WEDM is used in tool and die making industries, automobiles, aerospace, nuclear, computer and electronics industries. Brass wire is used extensively as a wire electrode in WEDM. Various high performance electrodes like zinc coated, diffusion annealed, coated steel core wires etc. have been developed to satisfy the machining needs. This paper reviews the effects of various WEDM process parameters such as pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process response parameters such as material removal rate (MRR), surface roughness (Ra), wire wear ratio (WWR) and work related development in wire electrode's materials.