Residual Stress analysis of different Profiles produced by Wire-EDM in Structural Steel

Abstract

In this study residual stress analysis of different profiles produced by Wire EDM in structural
steel has been performed. The concept of moving heat source was utilized to simulate the
residual stress formation using finite element based ANSYS software. Numerical simulation to
cut different profiles like circular, triangle and square were carried out in ANSYS 2021 R2
using Gaussian heat flux profile. Effect of heat flux on output responses e.g., temperature,
equivalent stress, equivalent strain, and total deformation were determined. When the
perimeter remains same, WEDM process produces highest temperature during machining of
triangular profile whereas it is lowest for circular profile. In WEDM highest thermal
deformation of 0.76 mm occurs in circular profile while triangular profile generates lowest
thermal deformation of 0.60 mm.