Why does feed rate strongly affect roughness?
A higher feed rate increases material removal demand per unit time. If the wire, coolant, and machine cannot support it, roughness and chipping usually worsen.
Does lower feed always improve the cut?
Lower feed may improve surface quality, but it also reduces productivity and can increase rubbing if the wire is not cutting efficiently.
What is a practical feed-rate test?
Run several short cuts at fixed wire speed and tension while changing feed rate. Compare cut time, kerf, roughness, chipping, and wire condition after each cut.
Application reference
For commercial equipment or test-cut planning, see Ensoll's test cutting service.