Modeling and Simulation of Wire Electrode Deflection in WEDM

In the process of wire electrical discharge machining, the wire electrode inevitably suffers bending deformation due to wire tension, electrostatic force, electrodynamics force, etc., and the deflection would make an clearly negative impact upon the machining accuracy, productivity and stability. In this paper, first of all, a novel modeling and simulation method is proposed for quantitatively calculating the wire deflection. Secondly, the mainly impact factors and trend of wire deflection have been concluded. Moreover, the feasibility of the model is proved by comparing with other researchers models. Eventually, the practical approaches of reducing wire deflection and improving the machining accuracy have been proposed.