Wire cut Electro Discharge Machining is a process in which removal of material

takes place by spark erosion of workpiece. In micro-wire electrical discharge

machining (micro-WEDM), the machined kerf width varies with different
machining parameters, which greatly influences the machining precision. In order to
study the kerf variations in micro-WEDM, the mathematical model of wire lateral
vibration in machining process is established and its analytical solution is
obtainedKerf Width is an important parameter in analysis of WEDM. It is used to
produce complex shapes and small holes, which are impossible to machine by
traditional methods. It is commonly used for machining of very hard and tough
materials such as tool steels, carbides, finishing parts for surgical, automotive and
aerospace industries, etc.
Kerf Width is considered as an important parameter in analysis of WEDM. Kerf is
defined as the width of material that is removed in a machining process. It has a
direct impact during machining of costlier materials. So, the Kerf Width has to be as
minimal to reduce the losses of machining.
Wire cut Electro Discharge Machining is a process in which removal of material
takes place by spark erosion of workpiece. Spark Erosion of workpiece material is
carried out by spark induced. A channel of plasma generated by electric sparks
between two conductive materials (i.e. wire electrode and the workpiece).
This channel of plasma converted into thermal energy at a temperature range of
8000OC to 12000OC at a pulsating direct current input supply. Kerf Width is an
important parameter in analysis of WEDM. It is used to produce complex shapes
and small holes, which are impossible to machine by traditional methods. It is
commonly used for machining of very hard and tough materials such as tool steels,
carbides, finishing parts for surgical, automotive and aerospace industries, etc.
The electrode and work piece separated by a small gap are immersed in dielectric
fluid. When the pulsating current is turned on generates an electric spark in small
gap, which erode the work piece material. As the pulsating current is turned off, the
plasma breaks down which leads to sudden reduction in the temperature and eroded
particles forms small microscopic debris. The eroded debris flushed away with the
help of dielectric fluid. With each electric spark discharge a small crater is formed
on both the work piece and the electrode which is a prime decider in the final
surface quality. In WEDM process de-ionized water is used as the dielectric fluid
which acts as insulator. Normal water contains minerals which may be too
conductive for WEDM process, in order to control the water conductivity; water is
de-ionized by passing it through a resin tank which eliminates the conductive
elements of water. This deionized water is circulated with the help of a pump. As the
machining operation is performed, conductivity of water rises and it is again
recirculated through the resin tank.
Fig 1 : Schematic representation of Wire Cut EDM process
Hang Tuah Jaya, 2014, investigated the cutting parameter on Kerf width using wire
electrical discharge machining (WEDM) of Inconel 718. The effect of three numerical
parameters namely the voltage gap, feed rate and current are studied. Response surface
methodology was selected as designs of experiment (DOE). ANOVA shows that feed
rate significantly affects the size of Kerf width compared to other parameters. The
optimization is done after the experiment has been validated by using the random
parameter and optimized parameter.
Roan M Kirwin, et al., 2018(ASME approved), investigated the effect of two non-
electrical parameters, wire tension and wire feed rate while machining Ti-6Al-4V in
wire EDM by designing a complex geometry. The complex designed shape consisted
of 3 different angles (45O, 90O and 112.5O) to investigate the error while angle or
corner cutting. In addition, the complex geometry also includes a thin wall section to
study the inaccuracies in kerf width. Workpiece of two different thickness were
machined to study how these experimental parameters coupled with workpiece
thickness can affect profile accuracy.
Di Shichun, et al., 2009, analysed the kerf width in micro-WEDM, which is composed
of 2 main parts: breakdown distance and the wire vibration amplitude. The wire lateral
vibration model in micro-WEDM process is built and the relationship between the
machining parameters and wire vibration amplitude is analysed. It explained the
variety of kerf width in the micro-WEDM process. It can be used as the theoretical
foundation for the kerf width control system. The open voltage not only determines the
breakdown distance but also affects the wire vibration in the process and it is
demonstrated to be a key factor to influence the kerf width in micro-WEDM. In order
to improve the machining precision, open voltage can be chosen to the main parameter
in the kerf width control.
Anshuman Kumar Sahu and Siba Sankar Mahapatra, 2018(ASME approved),
investigated the electrical discharge machining of titanium alloy (Ti6Al4V) using
AlSi10Mg tool electrode prepared via SLS process and copper and brass tool
electrodes. The following outcomes of the research work is as follows:
1. Better EDM performance can be achieved by decreasing discharge current and
pulse-on-time with the use of AlSi10Mg RP electrode.
Soham S. Mujumdar, et al., 2016(ASME approved), investigated the effect of
dielectric conductivity on the dielectric breakdown, plasma characteristics, and material
removal in micro-EDM process via a combination of modeling and experimental
approach. Single discharge experiments have been carried out using water with different
electrical conductivities as the dielectric medium. Using the discharge voltage and
current waveforms captured during each discharge, breakdown characteristics of water at
different electrical conductivities have been studied. Also, the resulting craters have been
analyzed to study the effect of the conductivity on the material removal in micro-EDM.
An enhanced micro-EDM plasma model has been developed to predict the effect of
dielectric conductivity on micro-EDM plasma by including the plasma chemistry
resulting from the presence of Sodium Chloride (NaCl) in water. The following
outcomes of the research work is as follows:
1. Simulation experiments were carried out to obtain model based predictions of the
effect of dielectric conductivity on dielectric breakdown and micro-EDM plasma
characteristics, viz., electron density, temperature, heat flux, plasma resistance, and
discharge energy. The model-based predictions of the breakdown characteristics of
water at different conductivities are compared with the experimental results.
2. Zero-dimensional micro-EDM plasma model for saline water predicts that an
increase in dielectric conductivity increases the electron density and heat flux at the
anode from the micro-EDM plasma, whereas it decreases the electron temperature,
plasma resistance, and the total energy of the discharge.
Farnaz Nourbakhsh, et al., 2013, studied the influence of zinc-coated brass wire on
the performance of WEDM is compared with high-speed brass. Also, the effect of
process parameters on the process performance was determined by performing
experiments under different machining conditions. The following are the outcomes of
their research work:
1. Experimental results of WEDM of titanium indicate peak current and pulse width
have significant effect on cutting speed and surface roughness.
M. Durairaj, et al., 2013, had done the experimental investigation on wire
electrical discharge machining of Stainless Steel (SS304) has been done using brass
wire of 0.25mm. The following are the outcomes:
The objectives such as surface roughness and kerf width are optimized using a
single objective taguchi method and multi objective grey relational analysis and the
same has been validated with the experimental results.
Adeel Ikram, et al., 2013, studied the the effect and optimization of eight process
parameters on three response variables namely surface roughness, kerf and MRR is
carried out using Taguchi’s design of experiment followed by comprehensive
statistical analyses (ANOVA and S/N ratio) to identify the key factors affecting
stated response variables. Moreover, mathematical models (multiple linear
regression and additive) are developed to establish the relationship between control
factors and performance measures. For kerf, the significant factors are pulse on-
time, wire tension and open voltage.
4. More research and experimentation with new combinations of core and coating
materials are needed for improving the machining efficiency, since existing wires do
not fulfil all requirements.
Harsimran Singh and Harmesh Kumar, 2015, have proved that WEDM is an
adequate machining process to machine aluminium matrix composites with good
surface finish and dimensional precision. Machining rate of composite is
significantly affected by the kind of reinforcement. To investigate the influence of
reinforcement research work is important but the influence of % volume of
reinforcement cannot be predicted. Mostly silicon carbide (SiC) reinforced
Aluminium Matrix Composites(AMCs) have been used in WEDM process for
machining purposes. In most of the research work, optimization of the process
parameters has been focussed on electrical parameters, whereas non-electrical
parameters like flushing pressure, dielectric conductivity, workpiece rotation and
electrode rotation are equally important