Analysis of Residual Material and Machining Error on Straight and Corner Curved Paths in Roughing of WEDM

Wire electrical discharge machining (wire-EDM) is able to generate delicate and complex shapes on hard materials which are difficult to cut. Inaccuracy in the cutting of small radius curved corners is one of the major problems in this process. In the present paper, corner radii machining errors have been investigated. Experiments are designed using the Full Factorial Method for roughing operations by considering frequency of discharges, wire tension and radius of curvature as variables, and the residual material on straight and curved paths as the output parameters. Practical works are implemented on tool steel 1.2510. By employing statistical techniques for analysis and by calculating variable side gap on curved corners, the machining error is obtained for 150, 300 and 450 µm radius curvatures. Results show that the thickness of residual material left on the workpiece on straight and curved paths can be the same if the cutting path on curvature is corrected according to the findings of this paper.