Corresponding Author

Sara A. El-Bahloul

Subject Area

Production Engineering and Mechanical Design

Article Type

Original Study


Wire electrical discharge machining (WEDM) is a specific form of electrical discharge machining that employs a small diameter wire electrode to cut a narrow kerf in the workpiece. Since the wire deflection has a negative effect on the performed cutting, this research seeks to study the resultant wire deflection during WEDM of AISI 304 stainless steel. This study is performed with the help of three types of modeling; namely, mathematical modeling, experimental modeling, and thermo-mechanical finite element modeling. The mathematical modeling is performed to analyze the stresses and the wire lag, while the experimental modeling is achieved to observe the wire deflection and the cutting forces. The thermo-mechanical finite element modeling is accomplished with the help of ABAQUS software to forecast the wire deflection and make a correlation between the experimental and computational works. The results indicate the accuracy of the proposed models. The obtained wire deflection increases at a shorter machining length then it is decreased. The wire deflection is larger in the case of cutting without working fluid compared to with working fluid. In addition, the direction of the wire deflection is in the same cutting direction in the case of without working fluid, while it is revered in the case of working fluid flow.


WEDM; Wire deflection; Mathematical modeling; Experimental modeling; thermomechanical finite element modeling

Creative Commons License

Creative Commons Attribution 4.0 License
This work is licensed under a Creative Commons Attribution 4.0 License.