Abstract: Magnetic materials serve as the primary structural components in electromagnetic mechanics and are among the essential materials for electric vehicles. Wire electrical discharge machining (WEDM) is widely employed for processing these conductive materials, where machining precision directly impacts material performance. This study utilizes brass wire, galvanized copper wire, and Cu-Zn double-coated steel wire (HSC wire) to conduct parallel cutting experiments on 20 mm thick ledeburite steel under constant process parameters using a FANUCα-C600iA machine tool. Each group underwent three repeated trials, with results validated through data validity processing and one-way analysis of variance. The experiments demonstrates that HSC wire exhibited optimal cutting performance, achieving an average speed of 1.05 mm/min (a 23% improvement over brass wire and a 15% improvement over galvanized copper wire), with statistically significant differences in cutting speeds among the three materials. The superior performance of HSC wire stems from its high substrate stability and excellent conductive loss-reduction properties of the coating, coupled with controllable comprehensive costs, making it commercially viable. Future research could focus on composite coatings, core material modifications, and eco-friendly materials to optimize electrode performance, while also evaluating critical metrics such as coating adhesion.

Key words: wire electrical discharge machining; lyellitic steel; cutting speed; cutting time

摘要： 磁性材料是电磁力学的主要支柱材料，也是电动汽车主要材料之一，电火花线切割 （WEDM）被广泛用于该类型导电材料的加工，其加工精度直接影响到材料的性能。研究采 用黄铜线、镀锌铜线、Cu-Zn 双层涂层钢丝（HSC 线），在恒定工艺参数下，利用 FANUCα- C600iA 机床对 20 mm 厚莱氏体钢开展平行切割实验，每组进行 3 次重复试验，经数据有效性 处理及单因素方差分析验证结果。实验表明，HSC 线切割性能最优，平均速度达 1.05 mm/min （较黄铜线提升 23%、较镀锌铜线提升 15%），且三种材料切割速度差异具有显著统计学意义。 HSC 线的优异性能源于其基底高稳定性与涂层优良导电抗损耗特性，综合成本可控，具备工 业应用价值。未来可围绕复合涂层、芯材改性及环保材料优化电极性能，并关注涂层附着力 等指标。

关键词: 电火花线切割；莱氏体钢；切割速率；切割时间