Dimensional Accuracy Achievable in Wire-Cut Electrical Discharge Machining

  • Mohammad Nazrul Islam
  • Noor Hakim Rafai
  • Sarmilan Santhosam Subramanian
Part of the Lecture Notes in Electrical Engineering book series (LNEE, volume 90)


Wire-cut electrical discharge machining (WEDM) is a popular choice for machining hard and difficult to machine materials with very close tolerances. However, the widely held assumption of the high accuracy of WEDM needs to be investigated, which is the primary aim of this research. This work presents the experimental and analytical results of an investigation into the dimensional accuracy achievable in WEDM. Three techniques—traditional analysis, the Taguchi method, and Pareto ANOVA—are employed to determine the effects of six major controllable machining parameters: the discharge current, pulse duration, pulse gap frequency, wire speed, wire tension, and dielectric flow rate on three key dimensional accuracy characteristics of the prismatic component parts—linear dimensional errors, flatness errors, and perpendicularity errors of corner surfaces. Subsequently, the input parameters are optimized in order to maximize the dimensional accuracy characteristics. The results indicate that the dimensional accuracy that is achievable in WEDM is not as high as anticipated.


Wire-cut discharge machining Dimensional accuracy Pareto ANOVA Taguchi methods 


  1. 1.
    Black JT, Koher RA (2008) Materials and processes in manufacturing, 10th edn. Wiley, HobokenGoogle Scholar
  2. 2.
    Hocheng H, Lei WT, Hsu HS (1997) Preliminary study of material removal in electrical discharge machining of SiC/Al. J Mater Process Technol 63:813–818CrossRefGoogle Scholar
  3. 3.
    Lee SH, Li X (2001) Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of Tungsten carbide. J Mater Process Technol 115:334–358Google Scholar
  4. 4.
    Yan M, Lai Y (2007) Surface quality improvement of wire-EDM using a fine-finish power supply. Int J Mach Tools Manuf 47:1686–1694CrossRefGoogle Scholar
  5. 5.
    Williams RE, Rajurkar KP (1991) Study of wire electrical discharge machining surface characteristics. J Mater Process Technol 28:486–493Google Scholar
  6. 6.
    Tasi K, Wang P (2001) Comparison of neural network models on material removal rate in electrical discharge machining. J Mater Process Technol 117:111–124CrossRefGoogle Scholar
  7. 7.
    Dauw DF, Beltrami ETHI (1994) High-precision wire-EDM by online positioning control. Ann CIRP 43(1):193–197CrossRefGoogle Scholar
  8. 8.
    Yan M, Huang P (2004) Accuracy improvement of wire-EDM by real-time wire tension control. Int J Mach Tools Manuf 44:807–814CrossRefGoogle Scholar
  9. 9.
    Han F, Zhang J, Soichiro I (2007) Corner error simulation of rough cutting in wire EDM. Precis Eng 31:331–336CrossRefGoogle Scholar
  10. 10.
    Islam MN, Rafai NH, Subramanian SS (2010) An investigation into dimensional accuracy achievable in wire-cut electrical discharge machining. Lecture notes in engineering and computer science: proceedings of the world congress on engineering 2010, WCE 2010, 30 June–2 July 2010, London, UK, pp 2476–2481 Google Scholar
  11. 11.
    Ross PJ (1988) Taguchi techniques for quality engineering. McGraw-Hill, New YorkGoogle Scholar
  12. 12.
    Park SH (1996) Robust design and analysis for quality engineering. Chapman & Hall, LondonGoogle Scholar
  13. 13.
    Groover MP (2010) Fundamentals of modern manufacturing: materials, processes, and systems, 4th edn. Wiley, DanversGoogle Scholar
  14. 14.
    Gladman CA (1972) Geometric analysis of engineering designs, 2nd edn. Australian Trade Publishing Pty. Ltd., SydneyGoogle Scholar
  15. 15.
    Bjørke Ø (1989) Computer-aided tolerancing, 2nd edn. ASME Press, New YorkGoogle Scholar
  16. 16.
    Farmer LE (1999) Dimensioning and tolerancing for function and economic manufacture. Blueprint Publications, SydneyGoogle Scholar
  17. 17.
    ASME Y (2009) Dimensioning and tolerancing. ASME, New YorkGoogle Scholar
  18. 18.
    Islam MN (1995) A CMM-based geometric accuracy study of CNC end milling operations. In: Proceedings of 6th International Conference on Manufacturing Engineering, Melbourne, 29 Nov–1 Dec 1995, pp 835–841 Google Scholar

Copyright information

© Springer Science+Business Media B.V. 2011

Authors and Affiliations

  • Mohammad Nazrul Islam
    • 1
  • Noor Hakim Rafai
    • 2
  • Sarmilan Santhosam Subramanian
    • 3
  1. 1.Department of Mechanical EngineeringCurtin UniversityPerthAustralia
  2. 2.Department of Manufacturing and Industrial EngineeringUniversiti Tun Hussein Onn Malaysia (UTHM)Batu PahatMalaysia
  3. 3.Holcim (Australia) Pty Ltd.GosnellsAustralia

Personalised recommendations