Abstract: In In order to investigate the impact of process parameters on machining quality in wire electrical discharge machining （WEDM）, a combination of COMSOL software and finite element analysis method was employed to perform transient thermal simulation analysis of single-pulse discharge during the WEDM process. The simulation simulated the formation mechanism of discharge craters and micro-surface morphology, while single-factor machining experiments were conducted to validate the accuracy of the simulation results. The findings revealed that both the radius and depth of discharge craters increased with an increment in pulse width and peak current, leading to elevated surface roughness and diminished surface quality. The experiment verified the interaction law between surface morphology and discharge parameters of WEDM, which has certain guiding significance for actual processing.