Wire electrical discharge machining technology from the perspective of geometric accuracy, cut surface quality and electrode wear

The article summarizes wire electrical discharge machining (WEDM) with a focus on the process principle, quality factors, and the development of wire electrodes. It is a non-contact machining method for conductive, hard-to-machine materials using controlled pulsed arcing in deionized water; accuracy and surface quality are determined by thermo-electrodynamic phenomena, pulse settings, flushing, and cooling. Multiple passes with lower energy improve roughness, geometrical accuracy, and surface integrity.

The text further analyzes the influence of parameters on kerf width and corner accuracy, including arcing gap phenomena (energy, gap size, hydraulic/electrostatic/electromagnetic forces) that affect material removal, wire deformation, and stability. It identifies sources of corner defects (wire bending, field reinforcement, loading variations) and provides strategies for their reduction: trajectory compensation, adaptive feed and pulse adjustments, wire tension and flushing control, sensor-based monitoring, and multi-stage finishing. A key role is played by the wire electrode (material, diameter, coating, strength), with a trend from copper and brass toward coated and multi-layered wires with higher performance, which increases productivity and reduces costs.