Investigation of experimental and numerical analysis of thermal load of WEDM on all metals through process parameters on wire electrode temperature

Abstract

The thermal load on wire electrode in a wire electrical discharge machining (WEDM) is the most important factor in predicting wire electrode breakage. Thermal failure of wire electrode may be expected when the maximum temperature of the wire crosses a critical value. The maximum temperature of wire electrode is a function of process parameters of the machine and hence the failure depends upon what settings we choose to run WEDM process. In this investigation, simulation is done using finite-difference thermal model for continuous pulse without clustering of the spark. The model is used for determining distribution of the temperature throughout the length of wire electrode and analyzed the significance of various factors on wire breakage. The outcome of the present simulation model is validated by comparing it with the works of other researchers followed by its validation through experiments. A parametric study is also done to determine the effect of input process parameters and their interaction on the temperature of the wire. For finding the interaction effect, analysis of variance analysis is carried out followed by developing an empirical model. The predictive performance of our simulation model and developed regression models is assessed by comparing them with experimental value. The regression model is found to be closer, with an average percentage deviation of −2.55% on the experimental dataset, compared to 2.64% for the simulation model. During the validation test, the minimum and maximum deviations are 0.08% and 0.20% for simulation versus regression model predictions, −3.31% and −1.65% for experimental versus predicted results, and 1.82% and 3.40% for simulation versus experimental results, respectively. It is observed through this study that temperature of wire electrode mainly depends on the intensity of sparks per unit area which is a function of the input parameters of the WEDM.