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Wire electrochemical machining with monodirectional traveling wire

Article  in  The International Journal of Advanced Manufacturing Technology · January 2015

DOI: 10.1007/s00170-014-6745-z

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Int J Adv Manuf Technol
DOI 10.1007/s00170-014-6745-z
ORIGINAL ARTICLE
Wire electrochemical machining with monodirectional
traveling wire
Yongbin Zeng & Qia Yu & Xiaolong Fang & Kun Xu &
Hansong Li & Ningsong Qu
Received: 7 July 2014 / Accepted: 18 December 2014
# Springer-Verlag London 2015
Abstract Wire electrochemical machining (WECM) is a
promising approach for the fabrication of various metal
parts. In WECM, the machining stability and accuracy
are significantly affected by the mass transport rate in
the machining gap. In this paper, a monodirectional
traveling wire is introduced in the WECM process to
remove the electrolysis products and renew the electro-
lyte in the machining gap. A flow field model of the
electrolyte in the machining gap is built. A machining
system with a monodirectional traveling wire unit has
been developed. Both the flow field model and the
experimental results illustrate that the monodirectional
traveling wire is a notably effective approach for
renewing the electrolyte and removing the electrolysis
products in a narrow machining gap during the WECM
process. Parameters such as the wire traveling velocity,
the feeding rate, and the applied voltage are optimized.
Finally, structures with uniform slit width on stainless
steel 304 with a thickness of 5 mm have been
fabricated.
Keywords Wire electrochemical machining . Traveling wire .
Mass transport . Machining stability
Y. Zeng : Q. Yu : X. Fang : K. Xu : H. Li : N. Qu (*)
College of Mechanical and Electrical Engineering, Nanjing
University of Aeronautics and Astronautics, Nanjing 210016, China
e-mail: nsqu@nuaa.edu.cn
N. Qu
Jiangsu Key Laboratory of Precision and Micro-Manufacturing
Technology, Nanjing 210016, China
1 Introduction
Wire electrochemical machining (WECM) is a metal cutting
process in which a metal wire acts as the tool cathode, and the
workpiece acts as the anode which is dissolved electrochem-
ically. WECM is a flexible technology that can be used to cut
various metal parts by moving the wire electrode or the
workpiece along a programmed path. WECM inherits the
advantages of electrochemical machining (ECM), including
electrochemical dissolution of conductive materials at atomic
sizes regardless of their hardness and the toughness of the
anode and there being no tool wear, heat-affected zones,
residual stresses, cracks, burrs, etc. [1–5]. As the wire elec-
trode is not worn out during the WECM process, it may be
used repeatedly. The technology has broad application pros-
pects in the fields of the aerospace industry, precision instru-
ments, biomedicine, and so on.
In WECM, the machining stability and accuracy are sig-
nificantly affected by the mass transport rate in the machining
gap [6]. Fresh electrolyte must be supplied timely and ade-
quately into the machining gap to maintain the electrochem-
ical reaction, and the electrolysis products, such as hydroxides
and hydrogen gas, must be removed promptly to keep the
electrolyte conductivity unchanged. Otherwise, electric short
circuits will frequently occur as electrolysis products accumu-
late in the machining gap, and the machining process will
become very unstable. Especially in processing a thick work-
piece (thickness more than a few millimeters), the limitation of
mass transfer becomes more pronounced as the machining
gap is very deep and narrow. Moreover, the common methods
that are used in a typical ECM process to enhance the mass
transport in the machining gap, such as high-speed electrolyte
flow (10–60 m/s) [1], pulsating electrolyte [7], orbital move-
ment of the electrode [8], and rotating cathode tool [9] might

not be applicable to WECM due to its unique characteristics.
The enhancement of the mass transport in the machining gap
during WECM so as to improve the machining stability and
the ability to cut thick workpieces is a research topic of great
interest.
When WECM is applied at a micrometer scale, it is called
micro-WECM. Typically, the thickness of a workpiece cut
using micro-WECM is less than 100 μm [10–13]. In micro-
WECM, an acidic solution is usually used because the work-
piece material is continuously dissolved into the acidic elec-
trolyte, and there is no insoluble sludge electrolysis product.
Kim et al. employed dilute H2SO4 to fabricate micro-features
on stainless steel plates [10, 11]. Zhu et al. used dilute HCl as
the electrolyte to cut various complex microstructures on
nickel plates [12]. Wang et al. investigated the influence of
tool vibration on micro-WECM and found that low-frequency
and small-amplitude tool vibration was an effective way to
remove electrolysis products and renew the electrolyte in
micro-wire ECM [13].
For the WECM process, many other efforts have been
made by the research community to accelerate the mass trans-
port rate in the machining gap. El-Taweel et al. employed an
electrolyte jet flow to renew the electrolyte in a wire electro-
chemical turning process [14]. Bejar et al. also employed an
electrolyte jet flow to renew the electrolyte in WECM [15].
Wang et al. reported that microstructures on stainless steel 304
with a thickness of 5 mm could be machined using WECM
with the electrolyte flushing along the wire [16]. Wang et al.
demonstrated that traveling wires could improve the surface
integrity and material removal rate markedly in an abrasive
electrochemical multi-wire saw method [17]. Zeng et al. re-
vealed that a traveling wire is capable of producing micro-
structures having feature heights up to 10 mm and feature
aspect ratios of 50 or more [6]. Qu et al. demonstrated that a
combination of a reciprocated traveling wire electrode and
pulse ECM could enhance the accuracy of WECM [18]. A
review of the literature has revealed that the linear motion of
the wire electrode along its axis during the machining process
is an effective way to remove the electrolysis products and
renew the electrolyte in the machining gap.
In this paper, a monodirectional traveling wire is intro-
duced into the WECM process to remove the electrolysis
products and renew the electrolyte in the machining gap.
Compared with electrolyte flushing and reciprocated traveling
wires, the monodirectional traveling wire might offer some
advantages, such as more uniform flow in the machining gap
and no directional error, which are helpful for improving the
process stability and accuracy. A flow field model of the
electrolyte in the machining gap is built. A machining system
with a monodirectional traveling wire unit has been devel-
oped. Experiments have been carried to optimize the working
parameters, such as the wire traveling velocity, the feeding
rate, the applied voltage, and the electrolyte concentration.
Int J Adv Manuf Technol
Finally, structures with uniform slit width on stainless steel
304 with a thickness of 5 mm have been fabricated.
2 Principle of the proposed method
Figure 1 illustrates the principle of WECM with the
monodirectional traveling wire. The wire acts as the cathode
and the workpiece as the anode. The wire travels along its
axis, and the wire traveling direction is arranged to always
coincide with the direction of gravity in the machining region.
The electrolyte is forced to flow in the machining gap as the
wire is traveling. This is very helpful for removal of the
hydroxide electrolysis products. To keep the wire traveling
in one direction, a ring of copper wire is employed as the
cathode because the wire electrode is not worn out and may be
used repetitively in WECM, as shown in Fig. 2. During the
machining process, both the wire electrode and the workpiece
are immersed in the electrolyte and then the workpiece profile
can be formed by controlling the workpiece feed trajectory.
Direct current is used because the power of an ultrashort pulse
supply is insufficient.
In comparison to electrolyte flushing and a reciprocated
traveling wire, the main advantages of the monodirectional
traveling wire are as follows:
(I) It might provide more uniform flow in machining gap as
the wire is always traveling in one direction.
(II) It is very helpful for removing the insoluble sludge elec-
trolysis product from the machining gap as a result of the
effect of both the traveling wire and gravity.
(III) The risk of the wire breaking is decreased as the length
of the ring wire is much shorter than that of a recipro-
cated traveling wire.
(IV) There is no directional error because it is not necessary
to change the traveling direction periodically in contrast
to WECM with a reciprocated traveling wire.
Guide roller
Wire traveling direction Wire electrode
Gravity direction


Workpiece
Workpiece feeding direction DC voltage
Fig. 1 Schematic diagram of wire electrochemical machining with a
monodirectional traveling wire
Int J Adv Manuf Technol

Thus, the distribution of the flow velocity within the inter-

electrode gap can be expressed as
  
h2 dp y 2 U y U
ux ¼ − 1− þ þ ð5Þ
2μ dx h 2 h 2

10mm According to Eq. (5), with an increase of the wire traveling

velocity U, the flow velocity in the machining gap increases as
Fig. 2 Photographic view of a ring of copper wire with a wire diameter of does the electrolyte renewal rate, which is favorable for the
200 μm
removal of the electrolysis products. Almost all of the hydrox-
ides outflow from the lower end of the machining gap due to
3 Electrolyte flow field model
the effect of both the traveling wire and gravity, as shown in
Fig. 4. Therefore, the use of the monodirectional traveling
On the basis of Navier–Stokes equations,
wire in WECM could enhance the mass transfer rate and the
1 ∂p ∂ux ∂ux ∂ux ∂ux rate of electrolysis product removal from the machining gap,
f x− þ ν∇2 μx ¼ þ ux þ uy þ uz ð1Þ which could improve the stability and accuracy of the ma-
ρ ∂x ∂t ∂x ∂y ∂z
chining process.
As illustrated in Fig. 3, within the narrow machining gap,
the normal velocity component uy =0 and the pressure in the
machining gap only depend on the flow velocity component
4 Experimental system
along the x direction, that is, p=p(x). Therefore, the flow field
equations can be simplified as
The self-developed experimental WECM system with a
2 monodirectional traveling wire unit is shown in Figs. 5 and
1 d ux
− þν 2 ¼0 ð2Þ 6. The system consists of a machining feed system, an elec-
ρ dy
trolyte circulation system, and a traveling wire control system.
The machining feed system controls the expected motion of
the workpiece. The workpiece is mounted to the fixture
Because dp/dx is a function of x and is independent of y, the installed on the X–Y–Z stage, and the required contour is
integration of Eq. (2) yields


1 dp y2
ux ð y Þ ¼ þ C1y þ C2 ð3Þ
μ dx 2

Based on the boundary conditions, ux|y=h =U and ux|y=−h =0,

the integration constants are
U U 1 dp 2
C1 ¼ ; C2 ¼ − h ð4Þ
2 2 2μ dx

Fig. 3 Flow field model in the machining gap of the WECM process Fig. 4 Schematic view of electrolysis product distribution when using
with a monodirectional traveling wire the monodirectional traveling wire
 Int J Adv Manuf Technol

Computer

Data acquisition card

DC Power
Motion X-Y-Z stage
controller

Tension sensor
Z Wire feeding roller
Conductive
roller Precision linear
Yy positioning stage
xX Guide roller

Temperature sensor
PI
Heating tube
Tank

Electrolyte Workpiece Wire electrode Tension control roller

Fig. 5 Schematic of the experimental setup for WECM with a monodirectional traveling wire

obtained by the relative movement between the workpiece and
the wire electrode with the motion of the X–Y stage. The
electrolyte circulation system is designed for supplying fresh
electrolyte to the machining region and for filtering the prod-
ucts of electrolysis. The traveling wire control system, which
contains the main bracket, wire feeding roller, conducting
roller, guide roller, tension sensor, and precision linear posi-
tioning stage, is used to drive and control the tension of the
wire. The traveling of the wire is achieved by the friction
between the wire feeding roller and the wire electrode. The
machining region is located between the two wire guide
rollers. Additionally, the two lower wire guide rollers, im-
mersed into the electrolyte, should be insulated in case of the
effect of stray current during machining and to avoid electro-
lyte corrosion.
In order to retain the stability of the traveling wire, the
tensile force of the ring wire is monitored and adjusted by the
high-precision tension sensor and linear positioning stage in
real time. If the acquired tensile force is larger than that of the
preset maximum value, the linear positioning stage will loosen
the wire. Otherwise, if the acquired tensile force is smaller
than that of the preset minimum value, the linear positioning
stage will tighten the wire. Therefore, the tension of the wire is
kept within a reasonable range.

5 Experimental results and discussion

In WECM, the machined slit width Ds as well as its deviation

reveals the machining accuracy and process stability. As
shown in Fig. 7, the slit width Ds could be calculated as
follows:
Fig. 6 Photographic view of the experimental setup for WECM with a
monodirectional traveling wire Ds ¼ Dw þ 2Δs ð6Þ
Int J Adv Manuf Technol
Fig. 7 Schematic diagram of a side gap in WECM
where Dw is the diameter of a wire electrode and Δs is the side
machining gap. According to the electrochemical machining
principles, the side gap could be obtained from Eq. (7) [12].
rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2DW
Δs ≅Δb 1 þ ð7Þ
Δb
where Δb is the interelectrode frontal gap and described as
in Eq. (8).
ηωκU R
Δb ¼ ð8Þ
υW
where η is current efficiency, ω is the anodic material
electrochemical equivalent, κ is the electrolyte conductivity,
UR is the applied voltage, and υw is the wire electrode feeding
rate. As stated in “Section 1,” the electrolyte conductivity is
significantly affected by electrolysis products fraction β and
the electrolyte concentration with the format of Eq. (9).
2ð1−β Þ
κ ¼ κ0 ð9Þ
2þβ
where κ0 is the initial electrolyte conductivity and deter-
mined by the electrolyte concentration.
From Eqs. (7), (8), and (9), it could be concluded that the
slit width is influenced by the wire feeding rate, the applied
voltage, the electrolyte concentration, and the electrolysis
products fraction. In this study, the electrolysis products frac-
tion is changed through the wire electrode traveling. There-
fore, experiments were carried to explore the influences of
process parameters on the machining accuracy. Based on pre-
trials of stable machining, the machining parameters were
chosen in specific ranges which would be studied in the
following sections. Every experimental set contains five re-
peated trials. And the slit width was an averaged value of the
measured results.
5.1 The effect of the wire traveling velocity
Machining conditions for this set of experiments were as
follows: a wire diameter of 200 μm, applied voltage of 10 V,
NaNO3 solution of 6 g/L concentration at 29 °C, feeding rate
of 0.9 μm/s, workpiece (304SS) thickness of 5 mm, and wire
traveling velocity ranging from 0.005 to 0.03 m/s.
The variations of the slit width and its deviation with the
wire traveling velocity are shown in Fig. 8. It is noted that the
slit width increases with increasing the wire traveling velocity,
and the slit width deviation is much bigger when the wire
traveling velocity is either too slow or too fast. As indicated by
Eq. (5), the electrolyte velocity in the machining gap depends
upon the wire traveling velocity. When the wire traveling
velocity is increased, the electrolyte renewal is accelerated
and the electrolysis fraction β is decreased. As a result, the
electrolyte conductivity is increased as well as the machining
gap according to Eqs. (8) and (9). When the wire traveling
speed is too slow, such as 0.005 m/s, the electrolyte velocity is
also very slow and the electrolysis products generated in the
gap would cause electric short circuits. However, with a too
fast wire traveling speed, such as 0.03 m/s, radial swing of the
wire takes place due to the guiding roller oscillation, which
reduces the machining stability and produces irregular shapes.
The experimental results clearly reveal that the wire traveling
velocity has a significant effect on the processing stability and
machining accuracy. In this article, the optimal wire traveling
speed is 0.02 m/s.
5.2 The effect of the feeding rate
Machining conditions for this set of experiments were as
follows: wire diameter of 200 μm, applied voltage of 10 V,
NaNO3 solution of 6 g/L concentration at 29 °C, wire travel-
ing velocity of 0.02 m/s, workpiece (304SS) thickness of
5 mm, and workpiece feeding rate ranging from 0.3 to
1.5 μm/s.
As shown in Fig. 9, the slit width gradually decreases with
increasing feeding rate, and the slit width deviation decreases
370
360
350
Slit width (µm)
340
330
320
310
300
0.005 0.010 0.015 0.020 0.025 0.030
Wire traveling velocity(m/s)
Fig. 8 Effects of wire traveling velocity on slit width
 Int J Adv Manuf Technol

440 550

420
500
400
450
Slit width (µm)

380

Slit width (µ m)
360 400

340 350

320
300
300
250
280 5 10 15 20 25
0.3 0.6 0.9 1.2 1.5
Electrolyte concentration(g/L)
Feeding rate (µm/s)
Fig. 11 Effects of electrolyte concentration on slit width
Fig. 9 Effects of feeding rate on slit width

NaNO3 solution of 6 g/L concentration at 29 °C, wire travel-

accordingly except when the feeding rate reaches 1.5 μm/s.
ing velocity of 0.02 m/s, workpiece (304SS) thickness of
With the increase of the wire feeding rate, the machining time
5 mm, and applied voltage ranging from 8 to 12 V.
at a point is shortened and the material removal volume
Figure 10 shows the variations of the slit width and its
decreases. As a result, the machined slit width decreases
deviation with the applied voltage ranging from 8 to 12 V. The
according to Eq. (8). However, as the machining gap gets
figure shows that the slit width increases as the applied voltage
narrow, the electrolyte renewal gets difficult. Therefore, short
increases. As the voltage increases, the machining current also
circuits might occur frequently at a too high feeding rate, such
increases. Faraday’s law states that the material removal rate is
as 1.5 μm/s. For the improvement of the machining efficiency,
proportional to the machining current. So, the material remov-
a high feeding rate should be proposed under a steady ma-
al volume increases as well as the slit width, according to
chining process. The suggested feeding rate in this article is
Eq. (8).
1.2 μm/s.
However, the slit width deviation is much larger when the
The optimized feeding rate of 1.2 μm/s in WECM with the
applied voltage is 8 V. When the applied voltage is low, the
monodirectional traveling wire is much faster than that in
machining gap is too narrow to renew the electrolysis products
micro-WECM, which presently is less than 0.125 μm/s [11,
quickly. In a similar way, when the applied voltage is too high,
12], and faster than that in WECM with a reciprocated travel-
the amount of electrolysis products increases and could not be
ing wire, which is 1 μm/s [18]. A faster feeding rate has
taken away from the machining gap quickly. As a result, short
proven that the use of the monodirectional traveling wire is
circuits would take place, reducing the stability of the machin-
an effective approach for renewing the electrolyte and remov-
ing process and destroying the uniformity of the slit.
ing the electrolysis products in a narrow machining gap during
the WECM process so as to improve the machining efficiency
and stability.
5.4 The effect of the electrolyte concentration
5.3 The effect of the applied voltage
Machining conditions for this set of experiments were as
follows: a wire diameter of 200 μm, applied voltage of 10 V,
Machining conditions for this set of experiments were as
wire traveling velocity of 0.02 m/s, workpiece (304SS) thick-
follows: wire diameter of 200 μm, applied voltage of 10 V,
ness of 5 mm, NaNO3 electrolyte temperature of 29 °C, and
420 electrolyte concentration ranging from 6 to 24 g/L.
400

380
Slit width (µm)

360

340

320

300

280
8 9 10 11 12 (a) Groove (b) Micro-star structure
Applied voltage(V)
Fig. 12 Structures fabricated on stainless steel 304 with a thickness of
Fig. 10 Effects of applied voltage on slit width 5 mm
Int J Adv Manuf Technol
As shown in Fig. 11, the slit width and its deviation
increase with increasing electrolyte concentration. The elec-
trolyte conductivity increases with increasing the electrolyte
concentration. The increased electrolyte conductivity im-
proves the current density during the machining process,
which increases the volumetric material removal and enlarges
the slit width. Meanwhile, the increase of current density
would cause more electrolysis products. As a result, a small
electrolyte concentration is good for improving the accuracy
of WECM with a monodirectional traveling wire. In this
article, the optimal electrolyte concentration is 6 g/L.
6 Structure fabrication
As shown in Fig. 12, using WECM with a monodirectional
traveling wire, structures with uniform slit width in a sample
of stainless steel 304 and 5 mm in thickness have been
fabricated with the following optimal parameters: a wire trav-
eling velocity of 0.02 m/s, feeding rate of 1.2 μm/s, applied
voltage of 9 V, NaNO3 solution of 6 g/L concentration at
29 °C. The diameter of the wire electrode is 200 μm.
7 Conclusions
In this paper, a monodirectional traveling wire is employed in
WECM to enhance the mass transport in the machining gap.
Experiments have been carried out to investigate the influence
of process parameters, such as the wire traveling velocity, the
feeding rate, the applied voltage, and the electrolyte concen-
tration on the machining accuracy and stability. The conclu-
sions can be summarized as follows:
(1) The use of the monodirectional traveling wire is a nota-
bly effective approach for renewing the electrolyte and
removing the electrolysis products in a narrow machin-
ing gap during the WECM process.
(2) Appropriate increases of the wire traveling velocity and
the feeding rate could improve the machining accuracy
and stability, but excessive increases are detrimental. In
addition, low applied voltage and low electrolyte con-
centration are preferred for improving the machining
accuracy.
(3) Structures with uniform slit width in a sample of
stainless steel 304 and 5 mm in thickness had been
successfully fabricated using WECM with a
monodirectional traveling wire.
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Acknowledgments This work was conducted under the sponsorship of
the National Natural Science Foundation of China (51375238), the Jiang
Su Natural Science Foundation (BK20131361), and the Aeronautical
Science Foundation of China (2012ZE52068).
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