Study of particle size and position on debris evacuation during Wire EDM operations

Abstract

Abstract Wire Electrical Discharge Machining (WEDM) is a well-known non-conventional machining process for those applications that require both good finishing and tight tolerances. One of the main problems that occur during EDM operations is wire breakage, which leads to stops in the machining process and lowers process productivity. Recent findings have revealed that discharge accumulations near the same spot of the wire are the main cause for wire breakage. If this discharge accumulation is not stopped, the wire finally breaks. In the present work CFD simulations have been effectively used to simulate dielectric flow and particle movement. The effect of particle size and position, together with the effect of high and low pressure flushing conditions have been analyzed. The studied variables have a clear effect on debris evacuation, and it can be concluded that particle size and position, together with nozzle position affect process stability and wire breakage. This work can help to develop new WEDM strategies that consider the relation between mentioned variables and wire breakage.