Determining cutting parameters in wire EDM based on workpiece surface temperature distribution

  • S. Keith Hargrove
  • Duowen DingEmail author
Original Article


The material removal process in wire electrical discharge machining (WEDM) may result in work-piece surface damage due to the material thermal properties and the cutting parameters such as varying on-time pulses, open circuit voltage, machine cutting speed, and dielectric fluid pressure. A finite element method (FEM) program was developed to model temperature distribution in the workpiece under the conditions of different cutting parameters. The thermal parameters of low carbon steel (AISI4340) were selected to conduct this simulation. The thickness of the temperature affected layers for different cutting parameters was computed based on a critical temperature value. Through minimizing the thickness of the temperature affected layers and satisfying a certain cutting speed, a set of the cutting process parameters were determined for workpiece manufacture. On the other hand, the experimental investigation of the effects of cutting parameters on the thickness of the AISI4340 workpiece surface layers in WEDM was used to validate the simulation results. This study is helpful for developing advanced control strategies to enhance the complex contouring capabilities and machining rate while avoiding harmful surface damage.


WEDM Thermal damage FEM Temperature distribution Cutting parameters 


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This research was supported by the National Science Foundation’s Engineering Research Center for Reconfigurable Manufacturing Systems. The work is a partnership between the University of Michigan and Morgan State University in advanced manufacturing processes.


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Copyright information

© Springer-Verlag London Limited 2006

Authors and Affiliations

  1. 1.Clarence Mitchell, Jr. School of EngineeringMorgan State UniversityBaltimoreUSA

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