Study on the effect of three dimensional wire vibration on WEDM based on a novel thermophysical model
Wire electric discharge machining (WEDM) is one of the most important non-traditional manufacturing methods and widely utilized in aerospace and tooling industry. However, the lack of the accurate numerical description of the WEDM process impedes a better understanding of the WEDM process and its machining mechanism. Since the vibration of the wire significantly affects the discharge location and the temperature distribution of the workpiece, the thermophysical model of the WEDM is much more complex than that of the EDM. In this paper, based on the classical thermal model of the EDM, a novel finite element method (FEM) model of WEDM considering the three dimensional wire vibration was proposed to simulate the machining process and verified by a series of WEDM experiments. Eventually, the effects of the wire vibration on the material removal rate and recast layer thickness were investigated quantitatively by analyzing the simulation results of this new thermophysical model and corresponding experimental results.
KeywordsThermophysical model WEDM Three dimensional wire vibration Finite element method
Unable to display preview. Download preview PDF.
This research is supported by the National Natural Science Foundation of China (NSFC) under Grant No. 51705171, Pre-research Area Funds of “13th Five-Year Plan” Equipment under Grant No.61409230304, and the Guangdong Key Laboratory Construction Program under Grant No.2011A060901026.
- 7.Snoeys R, Van Dijck F, Peters J (1972) Plasma channel diameter growth affects stock removal in EDM. CIRP Ann 21:39–40Google Scholar
- 28.Ming W, Zhang Z, Wang S, Huang H, Zhang Y, Zhang G (2017) Investigating the energy distribution of workpiece and optimizing process parameters during the edm of al6061, inconel718, and skd11. Int J Adv Manuf Technol 92(1):1–18Google Scholar
- 30.Murray JW, Clare AT (2012) Repair of edm induced surface cracks by pulsed electron beam irradiation. Int J Adv Manuf Technol 212(12):2642–2651Google Scholar
- 31.Huang H, Zhang Z, Ming W, Xu Z, Zhang Y (2016) A novel numerical predicting method of electric discharge machining process based on specific discharge energy[J]. Int J Adv Manuf Technol 1(88):409–424Google Scholar