Abstract This paper describes a novel simulation method for wire electrical discharge machining (EDM) in corner cut of rough cutting. In the simulation system, we analyzed the wire electrode vibration due to the reaction force acting on the wire electrode during the wire EDM, set up a geometrical model between the wire electrode path and NC path, and investigated the relationship between the wire electrode movement and the NC movement. From the simulation system, the wire electrode path could be obtained when the machining parameters such as the discharge current, the tension of the wire and the thickness of the workpiece were known. Simulations of the corner cut in right-angle machining, sharp-angle machining, obtuse-angle machining were carried out. By comparing the simulation results with experimental results, the feasibility of the simulation method was proved.
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