Wire Tension Research Articles

Machining performance analysis of wire-EDM for machining of titanium alloy using multi-objective optimization and machine learning approach

This study investigates the multi-objective optimization of process parameters in wire electrical discharge machining (WEDM) using titanium alloy grade 5 and zinc-coated brass microwire. The novelty lies in the comprehensive investigation of the effects of varying pulse on time (Ton), wire tension (WT), and wire feed rate (WF) on output responses, including surface roughness (SR), surface crack density (SCD), corner diameter (CD), and kerf width (KW). The Box-Behnken design, a sophisticated response surface methodology (RSM) technique, is employed to efficiently explore the complex relationships and interdependencies between these input and output parameters. The study's novel approach incorporates machine learning algorithms, including decision tree, light gradient boosting machine (LightGBM) and random forest, to predict the characteristics of the laser-cut components based on the input parameters. The contour plots generated provide valuable insights into the underlying patterns and associations between input and output features, aiding in the understanding of the WEDM process. The results reveal that the optimized values for SR, SCD, CD, and KW are obtained at specific machining conditions: Ton of 10 μs, WF of 3.79 m/min, and WT of 8 gf. Among the machine learning algorithms employed, random forest outperforms the others in predicting KW, SR, SCD and CD, exhibiting significantly lower mean squared error (MSE) and mean absolute error (MAE) values. This study contributes to the field of WEDM by providing a comprehensive analysis, incorporating advanced experimental design techniques and machine learning algorithms, which can aid in process optimization and quality control in manufacturing applications.

Evaluating the effectiveness of the TOPSIS approach for three-wire electrode machining of D2 steel using the wire EDM method

Due to the high demand for D2 steel as a tool material and the difficulty of the machine, optimization of process parameters in advanced manufacturing machines is needed. This study investigates three wire electrodes: brass, coated copper, and annealed copper, analyzing their impact on tool material. Employing 0.25 mm wires, 10 mm D2 steel cubes are cut for consistent comparison. An L27 orthogonal array tests six parameters at three levels, optimizing with analytic hierarchy process technique for order preference by similarity to the ideal solution (AHP-TOPSIS). The response parameters were the metal removal rate (MRR) and kerf width (KW). Pulse on/off time, wire tension, spark voltage, input current, and wire feed rate vary systematically for each wire. The tests validate the efficacy of the AHP-TOPSIS method in optimizing WEDM parameters and machining performance. ANOVA reveals pulse-on and pulse-off times as crucial factors for various wire electrodes. Under diverse conditions, pulse duration increases spark efficiency. Based on the AHP-TOPSIS method results, weights of outputs revealed that the annealed copper wire yields the highest MRR value (0.232 mm3/sec). The brass wire exhibited the lowest MRR value (0.127 mm3/sec) compared to the others.

Effect of Mg on the Microstructure, Mechanical Properties, and Surface Roughness of Functionally Graded A413 Composite: Machine Learning Approach at Wire‐Cut Electric Discharge Machining Zone

The present study assists the industrial sectors by implementing low‐weight high‐strength aluminium composite. The pristine magnesium as a reinforcement in three different weight percentages (3.5, 7, and 10.5) is utilized to fabricate the A 413 composite using centrifugal casting. The density analysis concludes a higher level of Mg inclusion prompts the material to save 3.9% of weight. Microstructural study of centrifugal casting specimens reveal a rich existence of hard phase Mg2Si in the outer zone, with its richness decreasing toward the inner zone. The tensile test result affirms the functionally graded nature of the material with the increasing trend of tensile strength from the inner to the outer. Fractured surface analysis concludes the existence of cracks and their propagation for the inner region specimen. The influence of magnesium on the surface finish of functionally graded composite at the wire cut electric discharge machining (WEDM) zone is predicted using a machine learning‐based random forest regressor (RFR) algorithm. The supervised learning algorithm declares that 10.5 wt% of Mg facilitates the minimal surface roughness of 0.229 µm with the optimal combination of parameters 6 A of current, 115 µs of pulse‐on time, 60 µs of pulse‐off time, and 8 N of wire tension.

Study on the Length of the Effective Vibration Area of the Catenary in a Pantograph–Catenary Interaction System

The effective vibration area includes most of the catenary vibration caused by pantograph–catenary interactions and is the basis of the real-time catenary model for hardware-in-the-loop simulation. However, while the length of the effective vibration area is one of the most important parameters of the real-time catenary model, it has not been fully studied at present. In this paper, the length of the effective vibration area is first investigated. A pantograph–catenary interaction model is developed based on the modal superposition method. After the validation of the model, the vibration energy distribution of the catenary is used to determine the length of the effective vibration area based on the converged total energy. The influence of vehicle velocity and contact wire tension on the vibration energy distribution and length of the effective vibration area is investigated. The obtained appropriate length of effective vibration area is validated by a real-time catenary model and online measurement data of the contact force. The investigation results show that the energy distribution of the catenary can accurately determine the length of effective vibration area, and it increases with increasing vehicle velocity but decreases with increasing contact wire tension. The appropriate length of effective vibration area should be at least 160 m (approximately three spans) in the pantograph–catenary system.

Role of friction and geometry in tuning the bending stiffness of topologically interlocking materials

Topologically interlocking material (TIM) systems offer adjustable bending stiffness controlled by external pre-stress, as shown in previous studies. This study focuses on a specific TIM system comprised of truncated tetrahedral particles interconnected via tensioned wires. The fabrication process involves weaving nylon wires through 3D printed truncated tetrahedrons that have longitudinal and latitudinal through-holes. By varying the tension applied to the wires, one can systematically control the overall bending stiffness of the TIM system. We change the surface friction and the contact angle between adjacent particles at a fixed wire tension, to study experimentally how they affect the system’s bending response. We inform experiments with Level Set Discrete Element Method (LS-DEM) simulations, to correlate surface friction and contact area changes with the system’s bending modulus. The numerical model is shown to be predictive and could be used in the future to evaluate designs of TIMs.

Minimization of wire-wound pressure vessel diameter based on distortion energy theory

This paper investigates the minimization of the diameter of wire-wound pressure vessels. The study is conducted in two stages. Firstly, the stresses arising from the wire winding of the vessel and the internal pressure application are extracted based on the distortion energy theory. It is assumed that the equivalent stress within the winding area in each layer, under the internal pressure condition, equals the allowable stress of the wire, and in the cylinder area, it does not exceed the allowable stress of the cylinder. The required number of layers and the wire tension during winding (two essential unknown parameters in the industrial winding process) are determined to satisfy these assumptions. In the second stage, the diameter optimization of the vessel is studied using the Distortion Energy (DE) theory. It is found that reducing the cylinder diameter results in a decrease in the vessel diameter. The occurrence of buckling or yielding in the cylinder is a limiting constraint for reducing the cylinder diameter. For validation, the results obtained from the derived equations are compared and confirmed against finite element results and the equations provided in the ASME code. Wire-winding simulation around the cylinder uses the element birth and death technique. The agreement between the derived equations and the code equations, as well as finite element results, is excellent. In the examined case study, using the DE theory leads to a 24 % reduction in wire consumption compared to the maximum shear stress (MSS) theory. In the optimization stage, the vessel weight is further reduced by 24 %. Compared to monobloc shells, the optimized wire-wound vessel weight based on the DE theory experiences a 77 % reduction.

Launch and recovery of a work class ROV through wave zone in small offshore service vessel

The deployment of remotely operated underwater vehicle (ROV) from a small offshore service vessel (OSV) based on single point mooring system (SPMS) method is recently adopted in offshore renewable energy sector. However, the tension spike in wire, also known as snap load, often occurs when the ROV passes through the wave zone in launching and lifting operation of deployment. In this study, a practical numerical model for predicting wire tension during launch and recovery of ROV is developed and validated by wave flume test of a 1:10 scaled model. The numerical simulations reveal that the ROV deployment at vessel stern along with an appropriate reduction of horizontal distance from the hull are reliable safety strategies for reducing wire tension. By adopting the new deployment strategy, the annual operational capacity can be expanded by approximately 6% when the safe operational limit of ROV under a significant wave height of 1.25 m. Based on the comprehensive numerical simulation, the newly developed safe operating envelope provides a further guidance for onboard ROV operation in the O&M of offshore wind farms.

Experimental investigations on coated copper wire and annealed copper wire electrodes in wire EDM machining through a comparative assessment employing the TOPSIS technique

Metals that are electrically conductive but are difficult to work with are typically machined using WEDM (Wire Electric Discharge Machining). The production of tiny components, which are challenging to mill using earlier non-traditional machining techniques, has undergone a substantial transformation thanks to these machines. Two wire electrodes coated copper wire and annealed copper wire electrodes are used for the testing in this investigation, and the analysis is completed utilizing the tool material. The workpiece material, D2 Steel, was cut into cubes that were 10 mm thick for the experiment, and a wire electrode with a diameter of 0.25 mm was used. Using an L27 orthogonal array, six input variables were employed at three different levels in the testing. The TOPSIS technique is utilized to optimize the output variables, leading to the determination of various output parameters, including Material removal rate (MRR), Kerf width (KW), tool wear rate (TWR), and surface roughness (SR). The chosen input variables include wire tension (WT), a gap voltage (GV), input current (IP), wire feed rate (WF), pulse off time (Toff), and pulse on time (Ton). The 10 mm-wide D2 steel was milled using two wire electrodes, and an ANOVA table was made to identify the factors that had the greatest impact on the WEDM parameters. The rank and ideal Wire EDM parameter values must be calculated using main effect plots and tables of replies. From this investigation, we can also draw the conclusion that for machining D2 steel, annealed wire electrodes provide greater MRR than coated wire.

Design exploration of the status detection system for car-mounted catenary tension compensation device

The tension compensation device is a critical component for maintaining constant parameters of the contact wire, such as tension, catenary height, and sag, in the overhead contact system. Its operational status directly affects the normal operation of the entire contact wire system. This paper provides a comprehensive review of existing tension compensation device state detection techniques and analyzes their shortcomings. By comparing with existing methods for monitoring cable tension, a vehicle-mounted contact wire tension compensation device state detection system based on the three-point bending method is proposed. This system can simultaneously monitor the operational status of the device at the line side and anchor section, issuing real-time warnings in case of abnormal device states and possessing significant application value. This study provides a reliable tool for railway operators to monitor the devices status and take timely maintenance and adjustment measures to ensure the normal operation of the contact wire system

Multi-objective optimization of wire electrical discharge machining process using multi-attribute decision making techniques and regression analysis

Wire electrical discharge machining (WEDM) is one of the most important non-traditional machining methods that is widely used in various industries. The present research work is concerned with the influences of process variables on quality of machined specimen obtained from WEDM process. The process parameters to manufacture mold structure included wire feed speed, wire tension and generator power, and in the current research, the effects of these variables on the aim factors, namely dimensional accuracy, hardness and roughness of product surface have been investigated, simultaneously. In order to obtain the optimal experiment, the multi-objective optimization with discrete solution area has been employed. Method based on the removal effects of criteria (MEREC) and weighted aggregates sum product assessment (WASPAS) techniques have been used with the aim of weighting the objective functions and discovering the best practical experiment. In the following, the regression analysis has been employed to study the effects of variables on response factors. A good correlation between the results gained from two analysis methods was observed. Based on MEREC-WASPAS hybrid technique, the weights of roughness, hardness and dimensional accuracy of machined part were calculated to about 89%, 9% and 2%, respectively. In the selected optimal experiment, the amount of wire feed speed, wire tension and generator power variables were considered to, in turn, 2 cm/s, 2.5 kg, and 10%.

Study on the therapeutic effect of Kirschner wire tension band combined with anchor cross-stitch technique in the treatment of comminuted patellar inferopolar fractures.

Fractures of the inferior patellar pole, unlike other patellar fractures, present challenges for traditional surgical fixation methods. This article introduces the clinical technique and outcomes of using Kirschner wire tension band combined with anchor screw cross-stitch fixation for comminuted inferior patellar pole fractures. This retrospective case series study included 14 patients with comminuted inferior patellar pole fractures treated at our institution from September 1, 2020, to April 30, 2022. All patients underwent surgery using the Kirschner wire tension band with anchor screw cross-stitch technique. Follow-up assessments involved postoperative X-rays to evaluate fracture healing, as well as clinical parameters such as healing time, Visual Analog Scale (VAS) scores, range of motion (ROM), and Bostman scores. All patients were followed for an average of over 12 months, with no cases of internal fixation failure. Knee joint stability and function were excellent. X-rays revealed an average healing time of approximately 10.79 ± 1.53 weeks, hospitalization lasted 5.64 ± 1.15 days, surgery took approximately 37.86 ± 5.32 minutes, and intraoperative blood loss was 33.29 ± 8.15 ml. One patient experienced irritation from the internal fixation material. At the final follow-up, the Bostman score averaged 28.29 ± 0.83, knee joint flexion reached 131.07° ± 4.88°, all patients achieved full knee extension, and the VAS score was 0.36 ± 0.63. Kirschner wire tension band with anchor screw cross-stitch fixation for comminuted inferior patellar pole fractures delivered satisfactory clinical outcomes. This surgical method, characterized by its simplicity and reliability, is a valuable addition to clinical practice.

Finite element analysis of wire EDM process parameters on performance characteristics of Al–SiC hybrid composite with micro and nano reinforcements

Aluminum Hybrid Composites (AHC) microchannels find extensive applications in aerospace, refrigeration and air conditioning (RAC), microelectronics, automotive, biomedical, and marine industries due to their improved mechanical properties. The combination of lower density, high hardness, elevated thermal and electrical conductivity, superior elasticity, and heightened oxidizing ability at low temperatures makes machining aluminum hybrid composites challenging through orthogonal methods in an open environment. Therefore, it is imperative to investigate the impact of various machining conditions to determine optimal parameter values for microchannel fabrication in aluminum hybrid composite materials. This study aims to identify the ideal machining parameters for Al–SiC micro-SiC nano hybrid composites using wire electrical discharge machining. Four distinct process parameters (pulse on time, gap voltage, wire tension, and wire feed rate) and two response parameters (material removal rate (MRR) and surface roughness (SR)) were considered for process optimization. Additionally, finite element modeling was conducted for the aforementioned process, and the results were compared with experimental outcomes. Single-variable optimization yielded maximum MRR at 125 tons (μs), 25 SV (volt), 12 WT (kgf), and 2 WFR (m/min), and minimum SR at 125 tons (μs), 10 SV (volt), 12 WT (kgf), and 4 WFR (m/min). Single-variable optimization for simulations resulted in maximum MRR at 125 tons (μs), 40 SV (volt), 4 WT (kgf), and 6 WFR (m/min), and minimum SR at 110 tons (μs), 10 SV (volt), 12 WT (kgf), and 2 WFR (m/min). Precise modeling aids in minimizing unnecessary machining, enabling exploration of a broader range of experimental results, thereby promoting environmentally friendly and sustainable machining practices.

AN IN VITRO STUDY EXAMINING WIRE TENSION IN FINE WIRE CIRCULAR EXTERNAL FIXATION CONSTRUCTS

IntroductionIlizarov fixators are reliant on tensioned fine wires for stability. The tension in the wires is generated using specific tensioning devices. Loss of wire tension over time may lead of loss a stability and complications. A series of in vitro experiments were undertaken to explore wire tensioner accuracy, the impact of fixation bolt torque and initial tension on loss of tension in ilizarov constructs under static and dynamic loads.Materials & MethodsMedical grade materials were applied to a synthetic bone analogue using surgical instruments in all experiments. Bolt torque was fixed at 6, 10 or 14 Nm using a torque limiting wrench. Wire tension was assessed using a strain measurement bridge. Wires were tensioned to 90, 110 and 130kg as measured by a commercial dynamometric tensioner. Static and dynamic testing was undertaken using an instron testing machine. Cyclical loads from 50–750N were applied for 5000 cycles.ResultsActual wire tension was approximately 15% less than indicated by the tensioner device. Using fixation bolt torques of 10Nm and 14Nm achieved final wire tensions of around 60% and 80% of that applied at 90 and 130kg of applied tension. Static load testing demonstrated self stiffening to similar levels in all pre-tensions. Dynamic testing demonstrated significant loss of tension, most of which occured in the first 3 cycles, inversely proportional to the tension initially applied.ConclusionsThese experiments provides insight into the effect of initially applied wire tension on Illizarov mechanical performance. It is important surgeons understand how the different ways that these devices are applied affects mechanical performance. Further research examining what factors affect performance across different manufacturers equipment would therefore be relevant, alongside the development of novel fixation methods to reduce wire slippage and the further development of equipment for clinical use.

Failure analysis of strain clamps on a ± 800 kV transmission line

During X-ray testing of a ± 800 kV ultra-high voltage direct current transmission line tension clamp, it was found that the internal steel core had broken. To investigate the cause of the steel core fracture, the failed clamp was dissected and analyzed, including chemical material testing, mechanical performance testing, fracture morphology inspection, and analysis of the compression process of the tension clamp. A preliminary judgment was proposed on the cause of the internal steel core fracture of the tension clamp, And verification experiments and simulation analysis were conducted to preliminarily determine the cause of the steel core fracture, and it was ultimately concluded that the main reason for the steel core fracture was the incorrect compression sequence of the large cross-section wire tension clamp.

Rendezvous-PIERCE technique: establishing a channel through severe calcification in infrainguinal arterial lesions using needle rendezvous

BackgroundSevere calcification often prevents device passage and balloon expansion in cases of lower extremity artery disease. To address this limitation, we introduced a novel calcium modification technique called Rendezvous-PIERCE (R-PIERCE).MethodsA needle was inserted in a retrograde manner and advanced to touch the tip of an antegrade guidewire within the lesion. Then, the guidewire was advanced into the lumen of the needle to achieve partial guidewire externalization, also known as needle rendezvous. The needle was then introduced over the externalized guidewire under wire tension and repeatedly rotated and advanced across the lesion to modify calcified intimal plaques. Notably, this technique can be applied in the opposite direction.ResultsCase 1 involved a 68-year-old male with a calcified occlusion of the anterior tibial artery. An antegrade guidewire reached the midpoint of the occlusion; however, microcatheters and balloons could not pass through the proximal calcification. Therefore, R-PIERCE was used to modify uncrossable lesions. An antegrade 2.5-mm balloon crossed and dilated the lesion, achieving hemostasis at the needle insertion site. The antegrade guidewire successfully crossed the entire lesion and was dilated by the 2.5-mm balloon. Final angiography demonstrated successful flow. In Case 2, an 80-year-old male had a calcified femoropopliteal occlusion. An antegrade guidewire was advanced into the distal superficial femoral artery (SFA); however, no device could follow it. R-PIERCE was performed to modify the calcification from the distal to the medial SFA. The antegrade balloon successfully crossed and dilated obstructed lesions. Furthermore, the antegrade guidewire crossed the entire lesion, and the antegrade balloon was dilated. Final angiography revealed a successful flow without complications.ConclusionsR-PIERCE is useful for modifying complex calcified lesions during the wiring of occlusive lesions.

Experimental investigation on the surface quality of WEDM machined 20MnCr5 steel for gear application

This experimental study investigates the Wire-cut Electrical Discharge Machining (WEDM) of 20MnCr5 steel, a low alloy steel grade material which is intended for the production of gears, shafts and other parts which need high surface hardness and wear resistance. WEDM is a crucial manufacturing process for producing gears, shafts, spindles, and various mechanical components. The investigation focuses on three key performance parameters: profile error, material removal rate (MRR), and surface roughness (SR), employing five WEDM parameters—wire feed (Wf), wire tension (Wt), servo voltage (SV), discharge arc-off time (Toff), and arc-on time (Ton) - by employing the Taguchi L27 orthogonal array. The study reveals that, in comparison to arc-on time and servo voltage, wire feed rate and tension have a lesser impact. Higher arc-on time and servo voltage result in increased profile error, while reduced wire tension values elevate surface roughness. Recast layer formation has been explored under different WEDM input parameters, revealing its dependence on arc-on time, voltage, wire tension, and feed rate. Higher voltage leads to uneven surfaces with larger globules and deep craters, contributing to a thicker recast layer at higher arc-on time and servo voltage.

Investigation on the effect of corner error in WEDM taper cutting process of Ti–6Al–4V

ABSTRACT Wire Electrical Discharge Machining (WEDM) is a non-conventional manufacturing method known for producing high-quality surface finishes and relies on the condition that materials conduct electricity. However, corner inaccuracies arise in workpieces during corner cuts with this method. This study aims to investigate corner inaccuracies using a novel approach involving oblique cutting and considering parameters such as wire tension (WT), corner angle, taper ratio, nozzle gap, and dielectric flow rate (LQ). The lower and upper corners resulting from taper cutting are analyzed separately. Initially, the parameters were determined, and the experimental design was established using the Taguchi method. Subsequently, the Coordinate Measuring Machine (CMM) was employed to determine the point positions of the specimens. A unique software-based method was then utilized to analyze the obtained point positions, revealing deficiencies in the expected corner areas and exposing errors. Ultimately, the analysis of the results was conducted employing the ANOVA method, offering insights into the verification and outcomes of the conducted experiments. The study concludes that, when examining corner inaccuracies, the most influential parameters are wire tension and dielectric flow rate for both lower and upper corners in taper cutting.

EXPERIMENTAL STUDY ON WIRE ELECTRIC DISCHARGE MACHINING OF NIMONIC 90 USING COATED ELECTRODE

Abstract WEDM machine is an unconventional machine that got accepted in the industries because of its skill to machine any material precisely in the required shape and size. Wire electric discharge machine uses electrical energy to cut hard conductive materials. In the present study, Nimonic 90 a nickel-based superalloy is machined in WEDM using a zinc-coated brass wire electrode to study its surface characteristics and its machinability. Experiments were carried out with central composite design with controllable WEDM factors such as Pulse duration, Servo-voltage, and wire-tension were used to investigate machining performance such as material transfer rate (MRR) and average surface roughness (Ra).The second order quadratic models are developed between WEDM parameters and responses by regression analysis. Analysis of Variance was employed to validate the accuracy of the established statistical models and the impact of the process variables. The RSM based optimization was used to find the optimal process parameter of Wire Tension 11.962 N, Pulse on Time 79.785 µs and Servo Voltage 100 V to achieve maximum MRR of 5.3574 (mm3/min) and minimal Ra of 2.6513 (μm). The validity of the optimized values are verified by conducting confirmation experiments and found that errors are within the permissible limit. Further, the surface morphology of the WEDMed specimen was carried out through SEM to ascertain the mechanisms of material removal under the different settings of WEDM.

A Theoretical Method for Calculating the Internal Contact Pressure of Parallel Wire Cable during Fretting Wear

Fretting wear of the stay cable is an important factor affecting the service life of the cable. To accurately calculate the extent of fretting wear, it is necessary to calculate the internal contact pressure in the cable. Although there are many theories and experiments on the contact behavior between wires, there are still no theoretical formulations for calculating the distribution of contact pressure in stay cables. In this paper, by studying the transfer effect of contact pressure in the cable, the PIC (parallel wire cable internal point contact pressure) model for calculating the contact pressure in the parallel wire cable is proposed, considering the effects of wire twisting, sheath compression, and cable bending on the contact pressure. A finite element model corresponding to the contact mode between steel wires is established, and the effectiveness of the PIC model is verified through numerical simulation analysis and a comparison of the existing contact models. The results indicate that contact pressure caused by wire twisting (CWT) is superimposed layer by layer inwards, with the contact pressure increasing closer to the inner layers, and its magnitude is mainly related to the axial tension and twist angle. Simultaneously, on the same layer, contact points along the diagonal experience the greatest contact pressure. Contact pressure caused by sheath compression (CSC) is assumed to conform to the Boussinesq distribution, with the outer layers exhibiting greater contact pressure compared to the inner layers. Contact pressure caused by cable bending (CCB) conforms to the two-dimensional closely arranged contact force transmission model, has a clear layering phenomenon, and the contact pressure within the same layer does not change significantly. The magnitude of the contact pressure is exponentially related to the curvature of the cable and proportional to the tension of the cable, which explains the reason why the slip occurs later for the cables with high tensile forces. Among these three types of contact pressure, CWT is the greatest, followed by CCB, while CSC is the smallest. The theoretical analysis results show that factors such as wire radius, tension, torsion angle, and wire position have an impact on contact pressure. Contact pressure is transmitted along force chains within the cable, following the superposition law between layers. It is uncertain whether slip occurs in the neutral axis or in the outermost layer because of the different distributions of tangential force and interlayer frictional resistance between the layers of wires. Fretting wear simulations of two wires demonstrate that contact pressure has a significant influence on wear patterns, and the “averaging” of contact pressure is a major reason for achieving uniform interface wear. While the contact width increases proportionally with the contact pressure, excessive contact pressure can complicate the problem by changing the contact mode from gross slip to partial slip. This study provides a theoretical method for calculating contact pressures at any contact point within the cables in engineering practice.

Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

A highly advanced thermo-electric machining technique called wire electrical discharge machining (WEDM) can effectively produce parts with varying hardness or complicated designs that have sharp edges and are very difficult to machine using standard machining procedures. This useful technology for the WEDM operation depends on the typical EDM sparking phenomena and makes use of the commonly used non-contact material removal approach. Since its inception, WEDM has developed from a simple approach for creating tools and grown to an outstanding option for creating micro-scale components having the greatest degree of dimensional precision and surface finish characteristics. The WEDM method has endured over time as an efficient and affordable machining alternative that can meet the stringent operating specifications enforced by rapid manufacturing cycles and increasing expense demands. The possibility of wire damage and bent, nevertheless, has severely hindered the process’ maximum potential and decreased the precision as well as effectiveness of the WEDM process. The article examines the wide range of investigations that have been done; from the WEDM through the EDM process’ spin-offs. It describes WEDM investigation that required variables optimization and an assessment of the many influences on machining efficiency and accuracy. Additionally, the research emphasizes adaptive monitoring and control of the process while examining the viability of multiple approaches to control for achieving the ideal machining parameters. Numerous industrial WEDM applications are described with the advancement of hybrid machining techniques. The paper’s conclusion examines these advancements and identifies potential directions for subsequent WEDM research. The investigation on WEDM of metal matrix composites (MMCs) is also reviewed; along with the impacts of various cutting variables like wire feed rate (F), voltage (V), wire tension (WT), and dielectric flow rate on cutting processes outcomes like material removal rate (MRR), kerf width (Kw) and surface roughness (SR). In the present article, future directions for WEDM research were also suggested.