Comparative Analysis of Aluminium and Stainless Steel Fabrication by Wire-Cut EDM: Wire Breakage and Surface Roughness Characteristics

Abstract

Wire Electrical Discharge Machining (Wire EDM) is a widely used precision machining technology that uses controlled electrical discharges to shape conductive materials. The process involves varying wire EDM parameters, such as electrical conditions and feed rate, which are adjusted based on the machined material. Each discharge creates craters on the material's surface, and when these craters exceed a critical size, they increase surface roughness and contribute to wire breakage. Wire breakage often results from inappropriate electrical parameters and insufficient debris flushing, leading to poor surface quality and operational instability. This study investigates the relationship between surface roughness and wire breakage frequency for aluminum and stainless steel under varying process parameters in submerged and flushing modes. By closely monitoring wire breakage, which indicates roughened components and correlates with component size, the study suggests that wire breakage frequency can be used to predict surface roughness. Experimental results show that with increasing voltage, surface roughness also increases, with stainless steel exhibiting a nearly linear trend. However, aluminum displayed a deviation at higher voltages, indicating an optimal processing window. At 110V, wire breakage occurred, resulting in the highest surface roughness. The findings provide critical insights for optimizing Wire EDM parameters to improve surface finish and minimize wire breakage, enhancing machining efficiency and product quality.