Wire Cut EDM Process-A Review

Mechanical Engineering

Wire cut electrical discharge machining (WEDM) is one of the most emerging non conventional manufacturing process for machining materials which are hard to machine and intricate shapes which are not possible with conventional machining methods. The wire cut EDM is also known as wire electrical discharge machining and wire cutting. In this, a thin single-strand metal wire, usually brass, is fed through the work piece, submerged in a tank of dielectric fluid, typically de-ionized water. The optimum utilization of the capacity of WEDM process requires proper selection of machining parameters. WEDM is complex in nature and is controlled by large number of parameter. It has been observed that process parameters such as voltage, current and pulse related parameters (viz. pulse on time, pulse off time) are the most important parameters in EDM/WEDM. They along with interaction time (pulse width x frequency) dominate the output parameters viz., MRR, surface roughness, etc. The depth of crater, temperature generated and the resultant surfaces obtained (along with its constituents) are result of pulse energy applied. Various researchers have focused on these aspects and prescribe for supply of optimum energy which in turn avoids post process failures. 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), Kerf (width of Cut), wire wear ratio (WWR) and surface integrity factors. This paper also reviews various optimization methods applied by the researchers and finally outlines the recommendations and future trends in WEDM research.

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