Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

A highly advanced thermo-electric machining technique called wire electrical discharge machining (WEDM) can effectively produce parts with varying hardness or complicated designs that have sharp edges and are very difficult to machine using standard machining procedures. This useful technology for the WEDM operation depends on the typical EDM sparking phenomena and makes use of the commonly used non-contact material removal approach. Since its inception, WEDM has developed from a simple approach for creating tools and grown to an outstanding option for creating micro-scale components having the greatest degree of dimensional precision and surface finish characteristics. The WEDM method has endured over time as an efficient and affordable machining alternative that can meet the stringent operating specifications enforced by rapid manufacturing cycles and increasing expense demands. The possibility of wire damage and bent, nevertheless, has severely hindered the process’ maximum potential and decreased the precision as well as effectiveness of the WEDM process. The article examines the wide range of investigations that have been done; from the WEDM through the EDM process’ spin-offs. It describes WEDM investigation that required variables optimization and an assessment of the many influences on machining efficiency and accuracy. Additionally, the research emphasizes adaptive monitoring and control of the process while examining the viability of multiple approaches to control for achieving the ideal machining parameters. Numerous industrial WEDM applications are described with the advancement of hybrid machining techniques. The paper’s conclusion examines these advancements and identifies potential directions for subsequent WEDM research. The investigation on WEDM of metal matrix composites (MMCs) is also reviewed; along with the impacts of various cutting variables like wire feed rate (F), voltage (V), wire tension (WT), and dielectric flow rate on cutting processes outcomes like material removal rate (MRR), kerf width (Kw) and surface roughness (SR). In the present article, future directions for WEDM research were also suggested.