Abstract. Work piece surfaces produced by wire EDM can exhibit surface alterations resulting from rapid heating and quenching during machining. The thermally altered layers have tremendous impacts on mechanical properties of machined product. Multi-cutting passes of brass wire into stainless steel sheet SS304 has been suggested in this paper. Three holes was machined at one cutting passes, two cutting passes and three cutting passes respectively and the effect on surface roughness of machined steel was investigated. Visual micro-structure study has been done to explore the existence of white layer and Heat Affected Zone (HAZ) layer. Based upon experimental result, the surface roughness is decreased with the increment of cutting passes. The white layer only formed at first cutting part and did not appear at two and three cutting passes.
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