Skip to main content
SpringerLink
Log in

Study on discharge point distribution of finishing in high-speed wire electrical discharge machine based on potential difference method

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In order to improve the processing stability of high-speed wire electrical discharge machine (HS-WEDM), a new system for on-line monitoring discharge point distribution based on potential difference method was presented. Detecting discharge point distribution is a key aspect of the stable processing in HS-WEDM. When the discharge point distribution is concentrated, it is easy to cause the arc discharge, which damages the surface accuracy of workpiece and reduces the processing efficiency. In the proposed system, the voltage data processing was done using Labview and Matlab based on PC. Through the calibration experiment, the fitted line was obtained by least squares method to determine the position of discharge point on workpiece, whose maximum nonlinear error is less than 1%. Meanwhile, the method of simple regional partition was applied to the evaluation system of discharge point to evaluate the distribution of discharge point. It can evaluate the overall distribution of discharge point, but also get the distribution of discharge point in each region. In test experiments, Cr12MoV material was machined with molybdenum wire. The proposed system of discharge point was successfully used to determine the position of discharge point and evaluate the distribution of discharge point in different processing media. In addition, the effect of processing parameters, such as pulse duration, peak current, worktable feed, offset, pulse interval ratio and workpiece thickness on the uniformity of discharge point distribution, surface roughness, cutting speed, and actual depth of cut in water mist, was also analyzed.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Data availability

The data in this study is obtained or measured through the corresponding experiments, and the materials have been given in this paper. They can be used as a reference for the related researchers.

Referencesr

  1. Rajmohan K, Kumar AS (2017) Experimental investigation and prediction of optimum process parameters of micro-wire-cut EDM of 2205 DSS. Int J Adv Manuf Technol 93:187–201

    Article  Google Scholar 

  2. Dauw DF, Snoeys R, Dekeyser W (1983) Advanced pulse discriminating system for EDM process analysis and control. Ann CIRP 32(2):541–549

    Article  Google Scholar 

  3. Liu LC, Qiu MB, Shao CJ, Zhang M, Zhao JF (2019) Research on wire-cut electrical discharge machining constant discharge probability pulse power source for silicon crystals. Int J Adv Manuf Technol 100:1815–1824

    Article  Google Scholar 

  4. He XX, Liu ZD, Pan HW, Qiu MB, Zhang YJ (2017) Increasing process efficiency of HSWEDM based on discharge probability detection. Int J Adv Manuf Technol 93(9-12):3647–3654

    Article  Google Scholar 

  5. Yan MT, Wang PW, Lai JC (2016) Improvement of part straightness accuracy in rough cutting of wire EDM through a mechatronic system design. Int J Adv Manuf Technol 84(9-12):2623–2635

    Article  Google Scholar 

  6. Zhang GJ, Huang H, Zhang Z, Zhang YM (2019) Study on the effect of three dimensional wire vibration on WEDM based on a novel thermophysical model. Int J Adv Manuf Technol 100:2089–2101

    Article  Google Scholar 

  7. Ji YC, Liu ZD, Deng C, Fang LJ, Qiu MB (2019) Study on high-efficiency cutting of high-thickness workpiece with stranded wire electrode in high-speed wire electrical discharge machining. Int J Adv Manuf Technol 100:973–982

    Article  Google Scholar 

  8. Reolon LW, Henning Laurindo CA, Torres RD, Amorim FL (2018) WEDM performance and surface integrity of Inconel alloy IN718 with coated and uncoated wires. Int J Adv Manuf Technol 100:1981–1991

    Article  Google Scholar 

  9. Khatri BC, Rathod PP (2017) Investigations on the performance of concentric flow dry wire electric discharge machining (WEDM) for thin sheets of titanium alloy. Int J Adv Manuf Technol 92(5-8):1945–1954

    Article  Google Scholar 

  10. Boopathi S, Sivakumar K (2014) Study of water assisted dry wire-cut electrical discharge machining. Indian J Eng Mater S 21(1):75–82

    Google Scholar 

  11. Wang JQ, Wang T, Wu HH, Qiu F (2017) Experimental study on high-speed WEDM finishing in steam water mist. Int J Adv Manuf Technol 91(9-12):3285–3297

    Article  Google Scholar 

  12. Wang T, Chen YQ, Kunieda M (2003) Study on wire-cut electrical discharge machining in gas. Chin J Mech Eng 39(8):76–80

    Article  Google Scholar 

  13. Magabe R, Sharma N, Gupta K, Davim JP (2019) Modeling and optimization of Wire-EDM parameters for machining of Ni55.8Ti shape memory alloy using hybrid approach of Taguchi and NSGA-II. Int J Adv Manuf Technol 102:1703–1717

    Article  Google Scholar 

  14. Kumar A, Soota T, Kumar J (2018) Optimisation of wire-cut EDM process parameter by Grey-based response surface methodology. J Ind Eng Int 14(4):821–829

    Article  Google Scholar 

  15. Yang CB, Lin CG, Chiang HL, Chen CC (2017) Single and multiobjective optimization of Inconel 718 nickel-based superalloy in the wire electrical discharge machining. Int J Adv Manuf Technol 93(9-12):3075–3084

    Article  Google Scholar 

  16. Wu HH, Wang T, Wang JQ (2019) Research on discharge state detection of finishing in high-speed wire electrical discharge machine. Int J Adv Manuf Technol 103(5-8):2301–2317

    Article  Google Scholar 

  17. Zhang Z, Ming WY, Zhang GJ, Huang Y, Wen XY, Huang H (2015) A new method for on-line monitoring discharge pulse in WEDM-MS process. Int J Adv Manuf Technol 81(5-8):1403–1418

    Article  Google Scholar 

  18. Kunieda M, Lojima H (1990) On-line detection of EDM spark locations by multiple connection of branched electric wires. Ann CIRP 39(1):171–174

    Article  Google Scholar 

  19. Muto K, Shiota Y, Futamura S (1989) Study on observation of EDM processing and monitoring of discharging point with acoustic emission. Proceeding of 9th ISEM:301-304

  20. Dreskog LY, Novak A (1989) A method for EDM spark location detection. Proceeding of 9th ISEM:297-299

  21. Han Q, He Y (2002) Sensor system design of electromagnetic method for spark location detection in EDM. Chin Aviat Precis Manuf Technol 38(5):30–32

    Google Scholar 

  22. Li Y, Di SC, Feng XG, Zhao WS (1998) On-line detection of EDM spark locations using potential difference method. J Harbin Inst Technol 5(3):82–85

    Google Scholar 

Download references

Funding

This study is supported by National Natural Science Foundation of China (50975069).

Author information

Authors and Affiliations

  1. School of Mechanical and Power Engineering, Harbin University of Science and Technology, Harbin, 150080, Heilongjiang, China

    Haihui Wu, Tong Wang & Junqi Wang

Authors
  1. Haihui Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Tong Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Junqi Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The ranking of the authors in the manuscript has been sorted according to their contributions. All the authors have approved the ranking of authors and the affiliation and contact information of the corresponding author.

Corresponding author

Correspondence to Junqi Wang.

Ethics declarations

Ethical approval

Not applicable.

Consent to participate

All the authors listed have participated in the preparation of the manuscript and the related experiments.

Consent for publication

This manuscript is approved by all the authors for publication. It is the original research that has not been published previously, and not under consideration for publication elsewhere, in whole or in part.

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wu, H., Wang, T. & Wang, J. Study on discharge point distribution of finishing in high-speed wire electrical discharge machine based on potential difference method. Int J Adv Manuf Technol 118, 155–172 (2022). https://doi.org/10.1007/s00170-021-07942-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07942-2

Keywords

Search

Navigation