A computer-aided system for the optimization of the accuracy of the wire electro-discharge machining process

The wire electro-discharge machining process (WEDM) has become very popular in the tool-making industry, in which complex geometries with tight tolerances must be generated on difficult-to-machine materials. However, the requirements of accuracy imposed on the process by the users are growing day after day, and therefore strategies for the improvement of the precision must be developed. In this work, a hybrid computer-integrated system for the improvement of the accuracy of corner cutting that combines experimental knowledge of the process and numerical simulation is described. Based on a technological database and a user-friendly interface, the system allows the user to select the optimum cutting strategy, either by wire path modification (when productivity is the main concern) or by cutting regime modification (when high accuracy is required). Simulation supports the decision-taking process by reducing the cost and time-consuming experimental trials. The validity of the system has been tested through a series of case studies, which show the improvements in accuracy and productivity with respect to the commonly used strategies. Acknowledgements The authors wish to thank the Department of Industry of the Basque Government, for their support in the Research Project ‘High Efficiency Manufacturing’ (AEFAR IE01UN01).