Authors :
Suraj Kumar Tiwari; Dr. Praveen Kumar; Dr. Vaibhav Chandra
Volume/Issue :
RISEM–2025
Google Scholar :
https://tinyurl.com/mr3nmssp
Scribd :
https://tinyurl.com/4y22djh3
DOI :
https://doi.org/10.38124/ijisrt/25jul611
Abstract :
Wire-Cut Electric Discharge Machining (EDM) process is renowned for its high accuracy in cutting
conductive materials with intricate profiles. This process is widely used in industries such as aerospace, marine,
automotive, and electronics. This review paper broadly examined the impact of various input process parameters of
Wire-Cut EDM such as pulse-off time, pulse-on time, voltage, current, wire tension, and servo feed on machine
performance, including material removal rate (MRR), wire wear, and roughness. Various types of electrodes have
been developed to meet machining needs. The transition from traditional brass wires to innovative coated wires has
been analyzed, revealing enhancements in thermal conductivity, improved cutting speeds, and reduced erosion while
maintaining accuracy. It was found that the relationship between electrical and non- electrical parameters shows that
higher currents boost material removal rates but compromise surface finish. The review also highlights how hybrid
wires and eco-friendly materials address cost and sustainability concerns. The aim of this review paper is to serve as
a guide for researchers and practitioners seeking to understand the Wire-Cut EDM process and optimize input
process parameters.
Keywords :
Wire-Cut EDM Process, Pulse On/Off Time, Voltage, Current, MRR, Surface Roughness, Optimization.
Wire-Cut Electric Discharge Machining (EDM) process is renowned for its high accuracy in cutting
conductive materials with intricate profiles. This process is widely used in industries such as aerospace, marine,
automotive, and electronics. This review paper broadly examined the impact of various input process parameters of
Wire-Cut EDM such as pulse-off time, pulse-on time, voltage, current, wire tension, and servo feed on machine
performance, including material removal rate (MRR), wire wear, and roughness. Various types of electrodes have
been developed to meet machining needs. The transition from traditional brass wires to innovative coated wires has
been analyzed, revealing enhancements in thermal conductivity, improved cutting speeds, and reduced erosion while
maintaining accuracy. It was found that the relationship between electrical and non- electrical parameters shows that
higher currents boost material removal rates but compromise surface finish. The review also highlights how hybrid
wires and eco-friendly materials address cost and sustainability concerns. The aim of this review paper is to serve as
a guide for researchers and practitioners seeking to understand the Wire-Cut EDM process and optimize input
process parameters.
Keywords :
Wire-Cut EDM Process, Pulse On/Off Time, Voltage, Current, MRR, Surface Roughness, Optimization.
