A novel method of determination of wire lag for enhanced profile accuracy in WEDM

Wire bending due to gap force is a major cause of imprecision in WEDM applications. To achieve higher precision and accuracy the knowledge of gap force and wire lag is extremely essential. In the present research, an in depth study on wire lag phenomenon has been carried out. A novel method to measure gap force intensity and wire lag under any given machining condition has been proposed by developing an analytical model. Experiments were carried out to verify the proposed model. Beside this, the impact of wire deflection on profile accuracy during cutting cylindrical job has been investigated. Based upon the developed analytical model an effective method has been proposed to eliminate this inaccuracy using wire lag compensation technique. The research finding will lead to better understanding of the gap force phenomena and will promote significant development in the domain of high precision WEDM.