Numerical and Experimental Investigations on Wire Electrode Health during Wire Electric Discharge Machining Process

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Wire electric discharge machining (WEDM) is a widely used high-precision machining process. With growing demands of manufacturing sector, wire erosion and breakage act as major challenges during WEDM process. Although material removal from the workpiece is desirable to achieve the required shape and contour, wire erosion and damage are detrimental to the overall machining process. Wire wear reduces the wire strength and eventually causes the wire to fail, which is a significant disadvantage in the modern manufacturing sector. Frequent wire breakage adversely affects the product geometric precision, surface integrity, and productivity of the manufacturing establishments. The damages undergone by the wire also have a notable effect on the surface quality achieved by the workpiece during machining. To reinforce and enhance the effective utilization of the wire EDM process, it is very much essential to mitigate the frequency of wire failure. Thus, it is imperative to understand the causes of wire breakage and predict the frequency of its occurrence. Prediction and prevention of wire rupture will definitely provide some useful insights in achieving sustainable manufacturing with the desired product quality.
Supervisor: Joshi, Shrikrishna N
Wire Electric Discharge Machining, Erosion, Breakage, Residual Stress, Molybdenum, Zinc Coated Brass Wire