Development of a New Cost Performance Index (CPI) for Selecting the Most Suitable Wire Electrode in Wire-EDM Machining

Wire electrical discharge machining, commonly known as Wire-EDM (or WEDM), is a nonconventional process of machining complicated, precise parts of hard conductive materials without using costly grinding or forming tools. Efficient utilization of available wire electrodes for computer integrated-Wire-EDM is an important aspect of production economic, energy consumption, and material consumption of wire electrode and workpiece. In this research work, a new cost performance index (CPI) of the wire electrode for Wire-EDM was developed, considering the economical and ecological aspects. Using the newly developed CPI, identifying the most suitable wire electrode and cutting conditions, for achieving production economic and machining efficiency in Wire-EDM, can be attained. This is highly recommended to guide the operation planner to classify the various alternatives to identify the most feasible wire, not only to achieve higher machining performance, but also to consider the economical and ecological aspects as well as minimizing energy and natural resources consumption. This is socially beneficial and very essential in industrial practice.