A Review on Advances in Wire Electrical Discharge Machining

Wire electrical discharge machining has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials such as titanium, zirconium and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses, lots of researchers have attempted to optimize the process parameters. This paper reviews the advances in research of WEDM on relation between different process parameters, include pulse-on time, pulse-off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), cutting speed (Vc), surface roughness (Ra), and wire wear ratio (WWR) of the wire electrode. Effect of composition of material on the manufacturability of wire EDM has also been reviewed. And at last, wire failure analysis is discussed.