| Abstract: |
Regardless of the mechanical hardness of the material, electrically conductive materials can be precisely cut using a non-traditional thermoelectric machining technique called wire electrical discharge machining (Wire EDM). This review summarises what is now known about Wire EDM, looking at its basic ideas, important process variables, performance traits, and industrial uses. In order to erode material and create complicated shapes with little residual stress, the procedure uses a tiny wire electrode that travels constantly and regulated spark discharges in a dielectric liquid. Even though wire EDM has many benefits for cutting complex geometries and hard materials, problems including low material removal rates, recast layer formation, and wire breakage still exist. Recent developments in wire electrode technology, dielectric systems, process optimisation, and adaptive control techniques are all thoroughly examined in this work. It also highlights important research gaps, such as the requirement for micro-Wire EDM capabilities, AI-driven real-time optimisation, hybrid process development, and sustainable dielectrics. The results emphasise the changing significance of Wire EDM in precision manufacturing and suggest future research avenues to improve its effectiveness, precision, and range of applications. |
