Effect of discharge accumulation on wire breakage in WEDM process

In recent years, WEDM has been adopted in precision machining as an important alternative method because of its greater flexibility and lower wear cost compared with traditional machining, whereas wire breakage during is unignorable problem that influences the quality efficiency. Therefore, it a research topic considerable interest. This work focuses on exploring reason for breakage. Firstly, by observing after discharges using finite element method, complete thermal model considering both latent heat flushing efficiency was built. With this model, simulation crater finished. Then based result gotten from experiment, partition ratio to found 46.74% inverse fitting. After that, experiment done through locating position 50 before 34% were located within range 2 mm, minimum area cross-section only remained 41.88% original wire. kind decrease made stress higher than UTS caused The findings allow more in-depth understanding effect discharge accumulation