Study of wire electrical discharge machined surface characteristics

The main goals of wire electrical discharge machine (WEDM) manufacturers and users are to achieve a better stability and high productivity of the process, i.e., higher machining rate with desired accuracy and minimum surface damage. The complex and random nature of the erosion process in WEDM requires the application of deterministic as well as stochastic techniques. This paper presents the results of current investigations into the characteristics of WEDM generated surfaces. Surface roughness profiles were studied with a stochastic modeling and analysis methodology to better understand the process mechanism. Scanning electron microscopic (SEM) examination highlighted important features of WED machined surfaces. Additionally, energy dispersive spectrometry (EDS) revealed noticeable amounts of wire electrode material deposited on the workpiece surface.