Modeling of material removal morphology and prediction of surface roughness based on WEDM successive discharges

In this paper, a successive discharge material removal model is proposed to predict the surface roughness of EN-GJL-250 (gray cast iron) under different parameters wire-cut electrical machining (WEDM). Firstly, finite element method (FEM) was used analogue simulate distribution temperature and flow field in WEDM single pulse process. According principle energy conservation, morphology characteristic parameter size crater are simulated. Secondly, position determined by minimum gap width between initial workpiece electrode wire during establishment model. Simulation results show that magnitude has an important influence on crater. Due energy, increasing trend radius, depth, flanging height not synchronized, increase radius more obvious rapid. Meanwhile, final machined location points. Finally, same verify quality materials. Experimental good agreement with average relative error simulation experimental 8.26%.