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Research on the characteristics of multi-channel discharge in wire electrical discharge machining

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Abstract

The long-existing contradiction between cutting speed and surface quality in wire electrical discharge machining (WEDM) detrimentally hinders its further development and application. To address this problem, this work proposed a multi-channel discharge method that performs WEDM on several workpieces, each electrically insulated and connected to a pulse power supply with a resistor. As a result, the machining energy normally exerted on one plasma channel can be dispersed into multiple discharge channels when each pulse voltage is applied. Firstly, the mechanism of multi-channel discharge was theoretically illustrated. Secondly, machining waveforms and high-speed imaging of gap phenomena were captured to prove the feasibility of multi-channel discharge in high-speed WEDM (HSWEDM). Although the multi-channel discharge is stochastic, a certain probability exists due to the vibration of wire electrodes. Lastly, verification experiments were conducted to investigate the performance of multi-channel discharge. The results indicate that the multi-channel discharge can significantly improve surface quality without reducing cutting speed, thus achieving a better balance between productivity and surface quality.

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Acknowledgements

The authors extend their sincere thanks to those who contributed in the preparation of the instructions.

Funding

This work was supported by the National Natural Science Foundation of China (grant number 51975290).

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  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, 210016, Nanjing, China

    Hongwei Pan, Zhidong Liu & Cong Deng

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  1. Hongwei Pan
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  2. Zhidong Liu
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  3. Cong Deng
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Pan, H., Liu, Z. & Deng, C. Research on the characteristics of multi-channel discharge in wire electrical discharge machining. Int J Adv Manuf Technol 129, 3063–3071 (2023). https://doi.org/10.1007/s00170-023-12461-3

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