Study on high-efficiency cutting of high-thickness workpiece with stranded wire electrode in high-speed wire electrical discharge machining
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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.
KeywordsHigh-speed reciprocating traveling WEDM Stranded wire electrode High thickness High cutting speed
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The authors extend their sincere thanks to those who contributed in the preparation of the instructions.
This project is supported by the National Natural Science Foundation of China (Grant No. 51575271 and No. 51675272).
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