New materials require the use of advanced technology in manufacturing parts of complex shape. One of the modern non-conventional technology of manufacturing difficult to cut materials is the wire electrical discharge machining (WEDM). The article presents the results of theoretical and experimental research in the influence of the WEDM conditions and parameters on the shape deviation during a rough cut. A numerical model of the dielectric flow in the gap (ANSYS) was developed. The influence of the dielectric velocity field in the gap on the debris evacuation and stability of WEDM process was discussed. Furthermore, response surface methodology (RSM) was used to build empirical models for influence of the wire speed Vd, wire tension force Fn, the volume flow rate of the dielectric Qv on the flatness deviation after the WEDM.
The development of industry is determined by the use of modern materials in the production of parts and equipment. In recent years, there has been a significant increase in the use of nickel-based superalloys in the aerospace, energy and space industries. Due to their properties, these alloys belong to the group of materials hard-to-machine with conventional methods. One of the non-conventional manufacturing technologies that allow the machining of geometrically complex parts from nickel-based superalloys is electrical discharge machining. The article presents the results of experimental investigations of the impact of EDM parameters on the surfaces roughness and the material removal rate. Based on the results of empirical research, mathematical models of the EDM process were developed, which allow for the selection of the most favourable processing parameters for the expected values of the surface roughness Sa and the material removal rate.