Analysis of wire electrode shape and position error of MWEDM

During the micro wire electrical discharge machining (MWEDM), the micro wire electrode will deform under all kinds of force. A finite element analysis approach is presented for calculating the wire electrode deform. At first, the wire's stiffness matrix only by wire tension and that only by spark force were obtained independently, and then the total stiffness matrix and the wire max deform analytic expression were got and the influential factors were analyzed. The results show that the wire deformation can be reduced by increasing the wire tension and the wire rigidity, and decreasing the span between the guide pulleys, while providing the micro energy pulse power is the best choice.