Finite element modeling and optimization to prevent wire breakage in electro-discharge machining

One of the most important problems in wire electrical discharge machining is related to wire breakage. This research develops a simple finite element model and a new approach to predict the thermal distribution in the wire fairly accurately. The model can be used to optimize the different parameters of the system to prevent wire breakage. At any instant of time, the spatial heat distribution profile of the wire can be mapped on the transient analysis of any point on the wire traversing through all the heat zones from the top spool to the bottom end. Based on this principle, the finite element model and optimization algorithm are used to determine that the heat generated is the critical variable responsible for wire breakage. The model successfully predicts the thermal distribution profile accurately for various wire materials, for increased wire velocity and for reduction in heat transfer coefficient. This simple model is a precursor of development for 3-D finite element models that can describe the cross-sectional wire erosion as the workpiece cutting progresses. The modeling may lead to the development of a smart electro-discharge machining system with a sensor and feedback control to increase the cutting speed and minimize breakage.