Review on Recent Development in the Wire EDM Process

Abstract

The optimum selection of process parameters is essential for advanced machining processes as these processes incur high initial investment, tooling cost, operating and maintenance cost. This report shows the consideration of Modelling and Optimization aspect of Wire Electric Discharge Machining. Wire electrical discharge machining is a widely accepted non- conventional machining process for advanced material removal and profile cutting. It is based on material removal through a series of electrical discharges applied between two electrically conductive electrodes i.e. work piece and wire. Dielectric fluid is injected into the gap, which is the space between electrodes. Thus, there is no contact between tool and work piece during the process. Each discharge is generated as follows the WEDM machine power supply applies a voltage between work piece and wire. It starts the ionization period of the dielectric fluid, which is known as ignition delay time. Dielectric ionization induces the discharge that vaporizes all the material around. One of the main challenges in wire electrical discharge machining is to eliminate wire breakage. The present work highlights the development of mathematical models using response surface modeling (RSM) for correlating the inter-relationships of various Wire Electric Discharge Machining parameters such as Pulse on time, Pulse off time, Peak voltage, Water pressure, Wire feed, Machine speed , Cutting speed override, etc.