Review of improvements in wire electrode properties for longer working time and utilization in wire EDM machining

Wire electrical discharge machining (WEDM) is an important technology, which demands high-speed cutting and high-precision machining to realize productivity and improved accuracy for manufacturing hard materials. WEDM has experienced explosive growth and complexity of equipment as well as rising demand for the basic process tool (the wire electrode). Greater taper angles, thicker workpieces, automatic wire threading, and long periods of unattended operation make the selection of the ideal wire a much more critical basis for achieving successful operation. This paper focuses on the evolution of EDM wire electrode technologies from using copper to the widely employed brass wire electrodes and from brass wire electrodes to the latest coated wire electrodes. Wire electrodes have been developed to help user demand and needs through maximum productivity and quantity by choosing the best wire. In the final part of the paper, the possible trends for future WEDM electrode research are discussed.