Study on Thermal Effect of

Wire EDM

Ainifatiha binti Mohamed Sabilan

091050071
Bachelor of Manufacturing Engineering
Supervisor: Mr Mohd Zahiruddin bin MD Zain
Wire EDM
Thermal effect

electrode

Recast layer

HAZ layer

workpiece
Problem statement

 Effect of HAZ and recast layer is difficult to be measured and

observed on the workpiece. WEDM has low quality of workpiece
surface.

Objective
To develop physical thermal model of copper material by WEDM.

To understand adverse effect of heat applied on workpiece.

Recast layer (B. Izquierdo)
Energy distribution

energy distributed on
workpiece will causes
material removal and carried  The greater energy
away as debris, and the
distribution will increase the
remainder lost due to heat
recast layer thickness.
conduction (B.
Thomas R. Newton
Izquierdo)
Plasma radius

 The plasma channel

radius is bigger at the
end of the discharge
for greater discharge
current and greater
discharge energy.
 (A. Okada, 2010).
 Energy distribution
   debris  
Power density, Pe
X= Xdeb+ Xcon
Xdeb

Xcon

 Energy distribution,   = discharge current

X = discharge voltage
d = plasma diameter

𝑋𝑑𝑒𝑏,ratio of energy carried away by debris

𝑋𝑐𝑜𝑛,ratio of energy lost due to heat conduction
 Methodology
START

Research & literature

review about project

Calculating heat flux

Physical modeling

No
Meet
requirement
YES

simulation

End
 Thermal model

Parameter Unit
Discharge current, ie 16.06A

𝑋 . 𝑖 𝑒 . 𝑢𝑒
Discharge voltage, ue 20 V
 𝑃𝑒 = 2
𝑑 Discharge duration, te 4 µs
𝜋
4
Plasma Plasma diameter, d 200 µm
diameter,d

Properties of copper unit

density 8970 kg/m3
Thermal conductivity, k 393 W/m K
Specific heat capacity, c 385 J/kg K
Relationship between Pe and X
Relationship between temperature
distribution an X
Power density vs plasma diameter
Plasma diameter d=200µm
Plasma diameter d=100µm
Conclusion

 The power density is applied on the thermal

model. The temperature distribution shows the
formation of HAZ and the recast layer.
 The increase of the energy distribution ratio will
increase the power density.
 20% of energy distribution gives the lowest
temperature distribution on the workpiece.
 The temperature distribution for the bigger
plasma diameter will gives smaller temperature
distribution on the workpiece.
Recommendation

 An experiment should be conducted to validate the

predict result of the temperature distribution of
power density on the workpiece

 Further investigation should be done to minimize

the formation of HAZ and recast layer formation
on the workpiece and lead to the best surface
integrity of the workpiece. This will increase the
lifespan of the material and reduce defective
production during WEDM process