Abstract
Wire-EDM process produces complex two and three-dimensional shapes in electrically conductive workpieces by a continuously moving wire electrode. Frequent occurrence of wire rupture reduces the efficiency and accuracy of the wire-EDM operation. Thus optimising wire life and minimising wire breakage is a major concern in modern manufacturing industries. In the present work, a three-dimensional nonlinear transient thermal finite element model (FEM) is developed for the wire electrode to predict the temperature distribution and crater formation in the wire. The crater volume obtained in the wire can be used to evaluate the wire erosion rate and hence the life of the wire can be predicted during machining. Molybdenum wire which is most commonly used in WEDM is considered for analysis. The results obtained from the model were found to be in good agreement with the experimental data. These results can be used to predict the life expectancy of the wire electrode.
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