Investigating wire breakage during EDM with fractographic analysis

Abstract

Wire electrical discharge machining (WEDM) is widely used in various fields of production. Its disadvantages include a relatively low productivity rate caused by wire breakages among other factors. In this article, the method of fractographic analysis is used to study a wire that has undergone a breakage during machining. The results indicate that the tool–electrode is subjected to mechanical tension followed by a ductile fracture. The most probable reason of wire breakages is a decrease in the wire cross–section, which can be caused by an electrodes short circuit.