Abstract Wire electrical discharge machining (WEDM) is always significant for its high-precision machining. However, due to the generation of high discharge energy during machining, machined surfaces are often got distorted. These might be upgraded by choosing the correct tool with proper machining condition. The effects of the electrode materials and process parameters on different responses of WEDM like average surface roughness, recast layer thickness, and surface morphology are systematically examined here to enhance the knowledge of WEDM and its correlation with electrode property. The experiments have been carried out on one of the expensive steel namely Maraging steel 300 due to its applicability in tooling and aerospace industries. Plain brass wire, zinc-coated brass wire (ZCB), and silver-coated brass (SCB) wires are used as a tool electrode for analysis. Comparative experimental studies prove that among BW, ZCB, and SCB, the overall performance of SCB is commendable owing to the high-quality surface considering control parameters in low discharge energy level. However, the second-best performance is shown by ZCB.

中文翻译：

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具有各种电极丝的 WEDM 表面完整性研究：实验和分析

摘要 电火花线切割加工（WEDM）因其高精度加工而具有重要意义。然而，由于加工过程中产生的高放电能量，加工表面经常变形。这些可以通过选择具有适当加工条件的正确刀具来升级。这里系统地研究了电极材料和工艺参数对 WEDM 不同响应的影响，如平均表面粗糙度、重铸层厚度和表面形态，以增强对 WEDM 及其与电极性能相关性的认识。由于马氏体时效钢 300 在工具和航空航天工业中的适用性，因此对其中一种昂贵的钢进行了实验。普通黄铜线、镀锌黄铜线（ZCB）、镀银黄铜 (SCB) 线用作分析工具电极。对比实验研究证明，在 BW、ZCB 和 SCB 中，由于在低放电能量水平下考虑控制参数的高质量表面，SCB 的整体性能值得称赞。然而，第二好的表现是 ZCB。