Abstract
To further improve the technological indexes of high-speed wire electrical discharge machining (HS-WEDM) under conditions of high energy and high thickness while also solving the problem of an absent liquid medium and unsteady processing in the inter-electrode gap, a new type of stranded wire electrode used in HS-WEDM was designed to enhance the flow of the liquid medium and debris removal during the machining process. First, a simulation model of the inter-electrode gap flow field is established; the simulation analysis indicates that the capacity of carrying liquid medium with a stranded wire electrode is approximately 65% higher than with a normal wire electrode at a high workpiece thickness of 400 mm. Next, the special discharge characteristic of stranded wire electrode is summarized from the two aspects of effective discharge area and high-thickness workpiece. Third, a comparative experiment on cutting a high-thickness workpiece at high energy demonstrates a greater threshold of stable cutting speed (over 250 mm2/min) and stable material removal rate (142 mm3/min) at an average cutting current of 18 A with a stranded wire electrode, whereas the maximum cutting speed (155 mm2/min) at an average cutting current of 8 A with a normal wire electrode. Experiments prove that using a stranded wire electrode can significantly increase cutting speed and improve processing stability in the electrode gap under high-energy and high-thickness conditions.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Maher I, Sarhan AAD, Hamdi M (2015) Review of improvements in wire electrode properties for longer working time and utilization in wire EDM machining. Int J Adv Manuf Technol 76:329–351. https://doi.org/10.1007/s00170-014-6243-3
Fan SY, Zhang QJ, Chen HW, Zeng WX (2013) Nonlinear dynamics analysis of multi-cutting wire electrode in WEDM-HS subjected to working fluid considering the effect of debris. J Mech Sci Technol 27:3595–3605
Haas P, Pontelandolfo P, Perez R (2013) Particle hydrodynamics of the electrical discharge machining process. Part 1: physical considerations and wire EDM process improvement. The seventeenth CIRP conference on electro physical and chemical machining (ISEM). Procedia CIRP 6:47–52
He XX, Liu ZD, Pan HW, Qiu MB, Zhang YQ (2017) Increasing process efficiency of HSWEDM based on discharge probability detection. Int J Adv Manuf Technol 93:3647–3654
Wang W, Liu ZD, Shi WT, Zhang YQ, Tian ZJ (2016) Surface burning of high-speed reciprocating wire electrical diacharge machining under large cutting energy. Int J Adv Manuf Technol 83:2713–2720
Wan ZY (2008) Research on cutting technique in super-lager thickness WEDM [D]. Guangdong University of Technology 2008:2–5
Liu ZD (2014) The development trend of high speed reciprocating wire electrical discharge machining. Machining Technology of Aeronautics 19:40–45
Li MH, Bu FL (1996) Theoretical research on super-high thickness of WEDM [J]. Journal of Shanghai Jiaotong University 30(9):122–126
Liu ZD (2016) Development bottleneck and research strategy in reciprocating travelling WEDM [J]. Electromachining Mould 2016(S1):5–10
Xia LX (2015) Research on the discharge mechanism and the characteristic of compound dielectric fluid’s life in HS-WEDM [D] Nanjing university of Aeronautics and Astronautics 2015:1–2
Li CR, Liu ZD, Fang LJ, Pan HW, Qiu MB (2017) Super-high-thickness high-speed wire electrical discharge machining. Int J Adv Manuf Technol 2017:1–14
Zhang YQ, Liu ZD, Pan HW, Qiu MB (2017) Dielectric fluid lifespan detection based on pulse discharge probility in wire electrical discharge machining. Int J Adv Manuf Technol 92(1–4):1481–1491. https://doi.org/10.1007/s00170-017-0211-7
Liu ZD, Chen HR, Pan HJ, Qiu MB, Tian ZJ (2014) Automatic control of WEDM servo for silicon processing using current pulse probability detection [J]. Int J Adv Manuf Technol 76(1–4):367–374
Pan HW, Liu ZD, Li CR (2017) Enhanced debris expelling in high-speed wire electrical discharge machining. Int J Adv Manuf Technol 93:2913–2292
Zhang Z, Huang H, Ming WY, Xu Z, Huang Y, Zhang GJ (2016) Study on machining characteristics of WEDM with ultrasonic vi-bration and magnetic field assisted techniques. J Mater Process Technol 234:342–352
Wang J, Han FZ (2014) Simulation model of debris and bubble movement in consecutive-pulse discharge of electrical discharge machining. Int J Adv Manuf Technol 74:591–598. https://doi.org/10.1007/s00170-014-6008-z
Acknowledgements
The authors extend their sincere thanks to those who contributed in the preparation of the instructions.
Funding
This project is supported by the National Natural Science Foundation of China (Grant No. 51575271 and No. 51675272).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Ji, Y., Liu, Z., Deng, C. et al. Study on high-efficiency cutting of high-thickness workpiece with stranded wire electrode in high-speed wire electrical discharge machining. Int J Adv Manuf Technol 100, 973–982 (2019). https://doi.org/10.1007/s00170-018-2745-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2745-8