Effect of Various Process Parameters in Wire-Cut EDM- A Review

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.