Wire electrical discharge machining (WEDM) is widely used in machining of conductive materials when precision is considered as a prime importance. This work proposes a three dimensional finite element model (using ANSYS software) and new approach to predict the temperature distribution at different pulse time as well as stress distribution in wire. A transient thermal analysis assuming a Gaussian distribution heat source with temperature-dependent material properties has been used to investigate the temperature distribution and stress distribution. Thermal stress developed after the end of the spark and residual stress developed after subsequent cooling. The effect on significant machining parameter pulse-on-time has been investigated and found that the peak temperature sharply increases with the parameter.

Keywords : ANSYS, WEDM, Residual Stress, Thermal Stress, Temperature