High-performance wire electrodes for wire electrical-discharge machining - A review

Abstract

In a wire electrical-discharge machining process an electrically conductive workpiece is eroded ahead of a continuous moving wire by spark discharges, which are identical with those in conventional electrical-discharge machining. With wire electrical-discharge machining, convoluted shapes can be cut with a high degree of dimensional accuracy and good surface finish. The machining efficiency of wire electrical-discharge machining can be significantly improved by an adaptive adjustment of various machining parameters, such as, pulse width, pulse interval, dielectric fluid pressure, wire tension, servo reference voltage, etc. Improving the productivities of dies and achieving high-quality workpieces demand is expanding for high-performance wire electrodes. A considerable amount of research on development of wire electrodes for wire electrical-discharge machining has explored high-performance wires for high-speed and high-precision machining. This article reviews the evolution of electrical-discharge machining wires from copper to plain brass to various coated, diffusion annealed and composite wire electrodes that significantly increase the wire electrical-discharge machining productivity. It is evident from the various research developments on wire electrode that they influence the wire electrical-discharge machining performance and improve wire electrical-discharge machining performance substantially. The possible trends for future research on electrical-discharge machining wire electrodes are also highlighted in this article. © 2012 IMechE.