Review of wire breakage causes and mitigation strategies in wire electrical discharge machining
Kanhaya Lal, Rajeev Trehan
Abstract
In an era of continuous technological advancement, the wire electrical discharge machining process has evolved to meet the ever-increasing demand for precision and efficiency in manufacturing. However, frequent wire breakages negatively impact the geometric precision, surface integrity and productivity of the wire EDM process. Therefore, understanding and mitigating the causes of wire breakage is critical. This state-of-the-art review article critically reviews experimental and theoretical research studies on multiple facets of wire electrode wear and failure. It discusses the influence of several control factors on wire electrode performance, including wire vibrations, bowing, forces acting on wire electrodes and thermal deformation. The article systematically analyses the proposed measures to enhance wire life and outlines the evolution of various wire condition monitoring and control systems. Furthermore, it also provides valuable insights and essential guidelines for optimizing the wire EDM process by addressing the factors contributing to wire erosion and failure. In the final section, the article explores challenges and potential future directions in this evolving field, emphasizing the importance of integrating machine learning and condition monitoring to enhance the continuous stability and efficiency of the WEDM process.