An investigation into the prediction of optimal machining conditions for polystyrene foam cut with a taut hot-wire

Abstract

A series of tests were undertaken in which the feed force, wire temperature and kerf width were recorded for expanded polystyrene foam (EPS) and extruded polystyrene foam (XPS) being cut with a hot-wire cutting-tool. From the gathered data general relationships between cutting parameters, material properties and kerf width (cut surface accuracy) were sought and developed. The findings reported in this paper provide an insight into the associated hot-wire cutting mechanics and the potential for consistently applying optimal cutting conditions during automated machining operations.