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Module-3: Advanced Material Removal Processes Lecture No-11 Wire Cut Electric Discharge Machining (WEDM)

The Wire Electric Discharge Machining (WEDM) process involves a thin metallic wire being fed through upper and lower diamond guides onto a submerged workpiece. Small electric discharges remove material from the workpiece as the wire moves in the x-y plane. WEDM can cut hard metals up to 300mm thick and is used to make punches, tools, and dies. Key parameters that affect the WEDM process include electrical parameters like peak current and pulse timing, non-electrical parameters like wire speed and flushing, and material properties.

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56 views28 pages

Module-3: Advanced Material Removal Processes Lecture No-11 Wire Cut Electric Discharge Machining (WEDM)

The Wire Electric Discharge Machining (WEDM) process involves a thin metallic wire being fed through upper and lower diamond guides onto a submerged workpiece. Small electric discharges remove material from the workpiece as the wire moves in the x-y plane. WEDM can cut hard metals up to 300mm thick and is used to make punches, tools, and dies. Key parameters that affect the WEDM process include electrical parameters like peak current and pulse timing, non-electrical parameters like wire speed and flushing, and material properties.

Uploaded by

Rajesh Punia
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Module-3: ADVANCED MATERIAL REMOVAL PROCESSES

Lecture No-11

Wire Cut Electric Discharge Machining (WEDM)

The Wire Electric Discharge Machining (WEDM) is a variation of EDM and is commonly known as wire-cut EDM or wire cutting.
In this process, a thin metallic wire is fed on-to the workpiece, which is submerged in a tank of dielectric fluid such as deionized
water. This process can also cut plates as thick as 300mm and is used for making punches, tools and dies from hard metals that
are difficult to machine with other methods. The wire, which is constantly fed from a spool, is held between upper and lower
diamond guides. The guides are usually CNC-controlled and move in the xy plane. On most machines, the upper guide can
move independently in the zuv axis, giving it a flexibility to cut tapered and transitioning shapes (example: square at the
bottom and circle on the top). The upper guide can control axis movements in xyuvijkl. This helps in programming the
wire-cut EDM, for cutting very intricate and delicate shapes.

In the wire-cut EDM process, water is commonly used as the dielectric fluid. Filters and de-ionizing units are used for controlling
the resistivity and other electrical properties. Wires made of brass are generally preferred. The water helps in flushing away the
debris from the cutting zone. The flushing also helps to determine the feed rates to be given for different thickness of the
materials. The schematic of wire cut EDM is shown in Figure 3.11.1 T g en
he WEDM

enerally use

ergy/power

echanical p

aterials whi

he selection

dergoes sig

rm recast

desired.

rocess of M

the WEDM

aterial is c

aterials are

moval take

process re

d when lo

per pulse i

roperties of

ch are not s

of process

nificant the

layers and
aterial Rem

process, th

ut/ remove

cut by the

s place by

quires lesse

wer residu

s relatively

the material

tress-relieve

parameter

rmal cycles

induce resi

oval in Wi

e motion o

d from th

WEDM pr

a series of

r cutting fo

al stresses

low (as in fi

are expecte

d earlier can

s is very cr

that can be

dual tensile

re-Cut EDM

f wire is slo

e workpiec

ocess by th

discrete disc

rces in ma

in the wo
nishing ope

d due to the

get distort

ucial, as in

very sever

stresses on

w. It is fed

e according

e electro-the

harges betw

terial remo

rkpiece are

rations), litt

se low resid

ed in the ma

some case

e. These th

the work

in the progr

ly. Electric

rmal mech

een the wi

val; hence

desired. I

le changes i

ual stresses

chining pro

s the work

ermal cycle

piece which

ammed path

ally condu

anisms. Ma
re electrode

it is

f the

n the

. The

cess.

piece

s can

are

and

ctive

terial

and

ed in between the tool-electrode gap thereby creating a path for each discharge. The area wherein discharge takes place gets
heated to very high temperatures such that the surface gets melted and removed. The cut particles (debris) get flushed away by
the continuously flowing dielectric fluid.

WEDM is a non-conventional process and is very widely used in tool steels for pattern and die making industries. The process is
also used for cutting intricate shapes in components used for the electric and aerospace industries.

Applications of Wire-Cut EDM

Wire EDM is used for cutting aluminium, brass, copper, carbides, graphite, steels and titanium. A schematic of the cutting
through wire EDM is shown in Fig. 3.11.2. The wire material varies with the application requirements. Example: for quicker
cutting action, zinc-coated brass wires are used while for more accurate applications, molybdenum wires are used.

The process is used in the following areas:

Aerospace, Medical, Electronics and Semiconductor applications

Tool & Die making industries.

For cutting the hard Extrusion Dies

In making Fixtures, Gauges & Cams

Cutting of Gears, Strippers, Punches and Dies

Manufacturing hard Electrodes.

Manufacturing micro-tooling for Micro-EDM, Micro-USM and such other micro

machining applications. T
T co
he Subsyste

Power

Dielec

Wire f

Positi
he power su

nventional

wire cut ED

the require

he drive sys

ntinuously

sue in WED

llers which

ower to the

ocess. The

ms of Wire

supply.

tric system.

eeding syst

oning system

pply and d

EDM. The m

M, a movi

d workpiece

tem continu

exposed to

M process.

direct the w

wire and gu

other parts

EDM

em.

i-electric sy

ain differe

ng wire elec

. The wire

ously deliv
the workpie

The wire f

ire through

ides it furth

are the pin

stem used i

nce lies only

trode is used

is wound on

ers the fresh

ce hence the

eeding syste

the machine

er in-order t

ch rollers w

n WEDM i

in the type

to cut com

a spool an

wire on-to

wear of th

m consists

. The presen

o keep it st

hich provid

s very simi

of dielectric

plex outline

d is kept in

the work a

e wire (tool)

of a large s

ce of metal
raight throu

e drive and

lar to that o

used.

s and fine d

constant ten

rea. New w

is not the m

pool of wire

contact pro

ghout the cu

wire tensi

f the

etails

sion.

ire is

ajor

and

vides

tting

on, a sy th
P
stem to thr

e wire runs

rocess Para

he process p

EDM proc

g.3.11.3. Th

Electr
voltag

Non-e

rate of
Electr
Dielec

ead the wire

out or break

meters in W
arameters t

ess are sho

e major para

ical paramet

e and polari

lectrical par

flushing.

ode based p

tric System

from the u

s.

EDM

hat can affe

wn through

meters are

ers: Peak cu

ty.

ameters: W

arameters: M

: Type, visc

pper to the l

ct the quali

an Ishika

as follows:

rrent, pulse

ire speed; w

aterial and

osity, and ot

ower guide

ty of machi

wa cause-e

on time, pu

ork feed rate


size of the w

her flow cha

and a senso

ning or cutt

ffect diagra

lse off time

, machining

ire.

racteristics

r to detect w

ing or drilli

m as show

and supply

time, gain

hen

ng in

n in

and

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