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A new approach for Micro-WEDM control based on Real-Time estimation of material removal rate

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Abstract

This paper describes a new approach for controlling a micro wire electrical discharge machining (μ-WEDM) process. In this approach, the relative feedrate of electrodes was controlled based on the real-time estimation of material removal rate and the identification of the workpiece height. An assisted vibration was applied to the workpiece, eliminating the limitation of a small discharge gap. This allows the electrode to be moved continuously, which cannot be performed in conventional WEDM. To verify the efficiency of the system, two workpieces with different shapes were used. For one workpiece, the height was varied linearly, whereas for the other, the height was varied non-linearly. The discharge current, discharge voltage, and number of discharge pulses were measured using current and voltage probes. The signal was uploaded to a computer through data acquisition devices, and a LabVIEW program was developed to estimate the feedrate and control the stages. The experimental results showed that the developed system worked effectively, with high machining stability and efficiency.

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Authors and Affiliations

  1. School of Mechanical Engineering, Kyungpook National University, 80 Daehak-ro, Bukgu, Daegu, 702-701, South Korea

    Kien Trung Hoang & Seung-Han Yang

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  1. Kien Trung Hoang
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  2. Seung-Han Yang
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Correspondence to Seung-Han Yang.

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Hoang, K.T., Yang, SH. A new approach for Micro-WEDM control based on Real-Time estimation of material removal rate. Int. J. Precis. Eng. Manuf. 16, 241–246 (2015). https://doi.org/10.1007/s12541-015-0032-2

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  • DOI: https://doi.org/10.1007/s12541-015-0032-2

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