Volume 8, Issue 1, January – 2023 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Analysis of WEDM Using ANSYS and FEM

Dheeraj Shukla*, Ashutosh Dwivedi
Student, Professor(H.O.D.)
Dept. of Mechanical Engineering, Vindhya Institute of Technology and Science, Satna

Abstract:- Wire electrical discharge machining (WEDM) of the part to be machined by the wire electrical discharge
is widely used in machining of conductive materials machining process. In 1975, it was popular rapidly, and its
when precision is considered as a prime importance. capability was better understood by manufacturing industry.
This work proposes a three dimensional finite element When the computer numerical control system was
model (using ANSYS software) and new approach to introduced in WEDM process this brought about a most
predict the temperature distribution at different pulse important development of the machining proce.
time as well as stress distribution in wire. A transient
thermal analysis assuming a Gaussian distribution heat Consequently the wide capability of the wire electrical
source with temperature-dependent material properties discharge machining process was widely exploited for any
has been used to investigate the temperature distribution through-hole machining owing to the wire, which has to
and stress distribution. Thermal stress developed after pass through the part to be machined. The common
the end of the spark and residual stress developed after application of wire electrical discharge machining process is
subsequent cooling. The effect on significant machining the fabricate the stamp and extrusion tools and dies, fixtures
parameter pulse-on-time has been investigated and and gauges, prototypes, aircraft and medical parts, and
found that the peak temperature sharply increases with grinding wheel form tools.
the parameter.
II. MATERIALS AND METHODS
Keywords: ANSYS, WEDM, Residual Stress, Thermal Stress,
Temperature. In the wire EDM, a series of rapid electric spark occur
in the gap between tool (wire) and workpiece. Addition of
I. INTRODUCTION particles into the dielectric fluid makes this process more
complex and random. The following assumptions are made
Wire electrical discharge machining process is a without sacrificing the basic features of the wire EDM
mostly used non-conventional material removal processes. model to make the problem mathematically feasible.
This is use for manufacturing difficult shape and profile of
hard materials. This is considering as a distinctive variation A. Thermal Model of Wire EDM
of the conventional electrical discharge machining The working principal of WEDM is as same EDM
processes. In the WEDM, demand is growing for high rate process, when the distance between the two electrodes (wire
cutting speed and high accuracy machining for improve the and the workpiece) is reduced the intensity of electric field
productivity of product and also for achieve high excellence in the volume between the electrodes (wire and the
quality in machining job. In wire electrical discharge workpiece), become greater than the strength of the
machining process a always travelling wire electrode made dielectric, which breaks, allowing current to flow between
of thin copper, brass or tungsten of diameter 0.05–0.3 mm is the two electrodes. For this reason the spark will generated.
used, which is precisely controlled by a CNC system. Here B. Finite Element Analysis Procedure Using ANSYS
role of CNC is very important. The function of CNC is Software
unwind the wire from a first spool, and feed throughout the
work-piece, and takes it on a second spool. Generally wire  Thermal Analysis of Brass Wire
velocity varies from 0.1 to 10 m/min, and feed rate is 2 to 6 The general finite element modeling procedure consists
mm/min. A direct current is used for generate high of the following steps:
frequency pulse to the wire and the workpiece. The wire
(electrode) is hold in tensioning device for decreases the  Preferences
chance of producing inaccurate parts. In wire electrical  Thermal
machining process, the workpiece and tool is eroded and
there is no direct contact between the workpiece and the  Preprocessing
electrode, and this reduces the stress during machining.  Definition of Element Type
 Material Properties Definition
WEDM was initially developed by manufacturing  Model Generation
industry in the since 1960. The development technique is  Meshing
replaced the machined electrode used in electrical discharge
machining. In 1974, D.H. Dulebohn introduced the optical
line follower system which is automatic control the shapes

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Volume 8, Issue 1, January – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
 Solution  Thermal>Heat Flux>On Element>Select Proper
 Defining Initial Condition Element>Ok
 Applying Boundary Condition  Initial Condition>Define>Pick All>Temperature>210C
 Applying Load  Solve >Current LS
 Solving For Results
 Post Processing>Plot Results>Counter Plot>Nodal
 Post Processing Solution>DOF Solution>Nodal Temperature>OK
 Reading Result File  Finish
 Viewing Results  Physics> Environment>Read >Structural>Ok
 Solution Control>Putting The Ton Time> Automatic
 Process of Thermo-Structural Modeling Time Stepping ON>No. Of Subsets
 Open Mechanical Apdl (Ansys).  Apply>Structural>Displacement>Area>All DOF>OK
 Go To File > Change Title And Give A New Title For  Solution Load Step>Write LS File>1>Ok
The Example.  Analysis Type>Solution Control>Basic>Off
 Preferences Time>Transient>Ramped Loading
 Preprocessing>Element Type> Add/Edit/Delete  Defineload>Apply>Temperature>From Thermal
Analysis>Brouse>File.Rth>Ok
 Click on Add
 Select Thermal Solid on the Left List and Brick 8 Node Post processing>plot results>counter plot>nodal
70 on Right List(I.E. Element Type) Click on Ok solution>DOF solution>nodal temperature>OK
 Close
 Material Properties>Temperature Unit>Celsius>Ok III. RESULTS AND DISCUSSION
 Material Models>Thermal >Conductivity>Isotropic>Ok
,Put Value>Density Put Value>Specific Heat Put A. ANSYS Model Confirmation
Value>Material Exit In this section we have firstly make a model of WEDM
 Modeling>Create>Cylinder>Sold Cylinder>Put the process for brass wire with parameter setting as given in
Dimensions Table 3. Later the value has been compared with Han et al.
 Meshing>Mesh Tool> Smart Size 6>Mesh >Ok Fig. 6 shows temperature distribution in brass wire, which is
approximately same of Han et al. model. So we can say that
we are proceeding in right way. Thermal modeling has done
in using ANSYS.

B. FEM Analysis
 Thermal Modeling of Wire EDM for Single Spark in
Brass Wire
Main parameters of the thermal analysis (analysis
parameters)

Table 1 Parameters Used for Thermal Analysis in

WEDM Process
Parameter Unit Value
Peak current of electro- A 27
discharge
Voltage of electro V 25
discharge,
Fig 1 Three-Dimensional View of the Meshed Model Duration of single pulse µs 0.12, 0.26, 0.36,
0.52, 0.58,
 Physics> Environment>Write >Physics File Wire radius Mm 1.2, 1.82
Title>Thermal>Ok Convective coefficient W/m2 0C 0.05
 Element Type>Switch Element Type>Change>Element Temperature of the 0C 3040
Type>Thermal To Structural>Ok dielectric Poisson’ ratio
 Material Coefficient of linear K1 21
Properties>Structural>Linear>Isotropic>Thermal thermal expansion
Expansion>Ok>Exit
 Physics> Environment>Write >Erase Thermal>Write
Structural>Ok
 Solution>New Analysis Type>Transient>Full>Ok
 Solution Control>Putting The Ton Time> Automatic
Time Stepping ON>No. Of Subsets
 Define Loads>Apply>Functions>Read File>Ok

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Volume 8, Issue 1, January – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig 2 Temperature Distribution In Brass Wire With V=25V, Fig 5 Temperature Distribution In Brass Wire With V=25V,
I=27 A, P=0.38 And Ton=0.12µs I=27 A, P=0.38 And Ton=0.52µs

Fig 3 Temperature Distribution In Brass Wire With V=25V, Fig 6 Temperature Distribution In Brass Wire With V=25V,
I=27 A, P=0.38 And Ton=0.26µs I=27 A, P=0.38 And Ton=0.58µs

Fig 4 Temperature Distribution In Brass Wire With V=25V, Fig 7 Temperature Distribution In Brass Wire With V=25V,
I=27 A, P=0.38 And Ton=0.36µs I=27 A, P=0.38 And Ton=1.2µs

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Volume 8, Issue 1, January – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig 8 Temperature Distribution In Brass Wire With V=25V,

I=27 A, P=0.38 And Ton= 1.82µs

 Structural Modeling of WEDM in Molybdenum Wire

Fig 10 Graph of Displacement
In this section we have firstly make a model of WEDM
process for brass wire with parameter setting as given in
 Thermo-Structural Analysis of WEDM in Brass Wire.
Table 4. Later the value has been compared with Saha et al.
 Thermal Stress Modelling of Micro Wire EDM for Single
Fig. 6 shows displacement molybdenum wire, which is
Discharge
approximately same of Saha et al. So we can say that we are
proceeding in right way. The structural analysis has done of
molybdenum wire.

 Displacement Analysis in the Wire Due to Tension:

After solving for the temperature distribution we
attempt to find the displacement in the wire. Now in this
case molybdenum wire is used. Process parameters used for
analysis is shown below Table 2

Table 2 Parameters used for structural analysis in

WEDM process
Parameter Units Value
Radius of wire Mm 0.125
Length of wire M
Tension N 0.1
Initial K
temperature Fig 11 Thermal Stress in X-Component at Ton=0.12µs
Working K 13.7295

 The displacement graph is shown in below:

Fig 12 Thermal Stress in Y-Component at Ton=0.12µs

Fig 9 Nodal Solution of Displacement

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Volume 8, Issue 1, January – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig 16 Thermal Shear Stress in YZ-Component at

Fig 13 Thermal Stress in Z-Component at Ton=0.12µs Ton=0.12µs

Fig 14 Thermal Shear Stress in XY Component at

Ton=0.12µs Fig 17 Residual Stress at Toff = 3µs

Fig 15 Thermal shear stress in XZ component at ton=0.12µs Fig 18 Thermal Stress in X-Component at Ton=0.52µs

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Volume 8, Issue 1, January – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig 22 Thermal Shear Stress in YZ-Component at

Fig 19 Thermal Stress in Y-component at ton=0.52µs Ton=0.52µs

Fig 20 Thermal Stress in Z-Component at Ton=0.52µs Fig 23 Residual Stress at toff= 3µs

Fig 21 Thermal Shear Stress in XY-Component at Fig 24 Thermal Stress in X-Component at Ton=1.82µs
Ton=0.52µs

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Volume 8, Issue 1, January – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig 25 Thermal Stress in Y-Component at ton=1.82µs Fig 28 Thermal Stress in XZ-Component at ton=1.82µs

Fig 26 Thermal Stress in Z-Component at Ton=1.82µs Fig 29 Thermal Stress in YZ-Component at ton=1.82µs

Fig 30 Residual Stress at Toff= 3 µs 2.5 Results and

Discussions

Temperature distributions at the end of the pulse time

Fig 27 Thermal Stress in XY-Component at Ton=1.82µs
are shown in Figs.(3- 9) to know the effects on WEDM. The

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Volume 8, Issue 1, January – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
temperature distribution during single discharge is 578.3350C. At pulse time = 1.2 µs, corresponding
calculated with the energy input constant parameter Ip= 27 temperature is 854.80C. At pulse time = 1.82 µs,
A, voltage =25V with varying pulse time. At pulse time = corresponding temperature is 11440C and the maximum
0.12 µs, corresponding temperature is 86.750C. At pulse compressive stress is 425Mpa for ton=1.82µs in Z-
time = 0.26 µs, corresponding temperature is 247.70C. At component, and maximum residual stress is 533 Mpa.
pulse time = 0.36 µs, corresponding temperature is 318.60C.
At pulse time = 0.52 µs, corresponding temperature is Further increasing the pulse time is not possible
446.90C. At pulse time = 0.58 µs, corresponding because, at temperature 10830C, the brass wire melt.
temperature is 578.3350C. At pulse time = 1.2 µs,
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