Monitoring sparking frequency and predicting wire breakage in WEDM

W. M. Wang, K. P. Rajurkar

Research output: Chapter in Book/Report/Conference proceedingConference contribution

19 Scopus citations


In the wire electrical discharge machining (WEDM) process, wire breakage (tool failure) reduces the machining productivity and also damages the machined surface. Most of the state-of-the-art WED machines attempt to prevent wire rupture by selecting a safe (longer) pulse off-time which limits the discharge frequency and slows down the machining speed. However, even with lower discharge frequency, wire rupture can not be completely avoided. This paper introduces a recently developed WEDM monitor to detect the sparking frequency for on-line control to avoid wire rupture and improvement of the machining productivity. With this new monitoring system, a large amount of sparking frequency data in the wire rupture process has been collected and analyzed, and vital characteristics have been identified. The factors affecting the wire rupture phenomena have been investigated. This paper also process an algorithm to predict wire rupture caused by high sparking frequency and unstable gap conditions.

Original languageEnglish (US)
Title of host publicationSensors and Signal Processing for Manufacturing
PublisherPubl by ASME
Number of pages16
ISBN (Print)0791807983
StatePublished - 1992
EventWinter Annual Meeting of the American Society of Mechanical Engineers - Anaheim, CA, USA
Duration: Nov 8 1992Nov 13 1992

Publication series

NameAmerican Society of Mechanical Engineers, Production Engineering Division (Publication) PED


OtherWinter Annual Meeting of the American Society of Mechanical Engineers
CityAnaheim, CA, USA

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Mechanical Engineering


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