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Modification and adaptation of wire lag model based on surface feed for improving accuracy in wire EDM of Ti-6Al-4V alloy

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Abstract

Dimensional accuracy in parts manufactured by wire EDM (WEDM) can be lost due to wire lag (where the wire electrode bends into an arc away from the machining direction). Wire lag effects are at issue when extremely narrow tolerances on curved or sharply angled geometries are desired. The feasibility of a program to modify machining G-code to compensate for wire lag at sharp corners is investigated here. Program development was informed by machining experiments. First, the effect of surface feed rate on profile accuracy was investigated. It was found that feed influences wire lag and profile accuracy. A wire lag model is demonstrated, and methods for developing modifications to incorporate both surface feed and eliminate the need for an ex situ measurement to minimize wire lag are presented. A method for relating pulse duration and voltage to each plasma discharge’s area is demonstrated. Lastly, an outline for a program that compensates for wire lag at threshold angles is shown. It is found that the developed application can predict wire lag or corner error within ±10% of the experimental value. It is also found that profile accuracy can be significantly improved using a cutback method by calculating the amount of wire lag from the modified model and modifying CNC G-codes using the developed application to apply cutbacks at designated corners.

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Acknowledgements

The authors would like to thank Miami University Center for Advanced Microscopy and Imaging (CAMI) for allowing to use the microscopy facilities.

Funding

The authors also would like to acknowledge the financial support from the Ohio Space Grant Consortium and Miami University Undergraduate Summer Scholars program.

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Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH, 45056, USA

    Roan M. Kirwin, James C. Moller & Muhammad P. Jahan

Authors
  1. Roan M. Kirwin
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  2. James C. Moller
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  3. Muhammad P. Jahan
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Contributions

Experimentation, modeling, analysis, and draft preparation: Roan Kirwin. Writing and editing: Roan Kirwin, James Moller, and Muhammad P. Jahan. Supervision: Muhammad P. Jahan. Funding: Muhammad P. Jahan (PI) and Roan Kirwin (graduate fellowship)

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Correspondence to Muhammad P. Jahan.

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Kirwin, R.M., Moller, J.C. & Jahan, M.P. Modification and adaptation of wire lag model based on surface feed for improving accuracy in wire EDM of Ti-6Al-4V alloy. Int J Adv Manuf Technol 117, 2909–2920 (2021). https://doi.org/10.1007/s00170-021-07870-1

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  • DOI: https://doi.org/10.1007/s00170-021-07870-1

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