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Wire breakage prevention for reciprocated traveling WEDM based on discharge location detection

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Abstract

This paper presents a wire breakage prevention method and a corresponding system for reciprocated traveling wire-EDM based on discharge location detection. The wire breakage risk is evaluated using the consecutive discharge concentration coefficient (CDCC) value and the number of arcs. CDCC characterizes the proximity of a sequence of consecutive discharge locations occurring in a short time, which takes both time and spatial domain into consideration. The system employs two fuzzy logic controllers to adjust machining parameters according to the degree of discharge concentration and the servo tracking performance detected. Verifications are conducted by cutting two workpieces with variable heights, including a stair-shaped and a hollow one. The machining tests show that the proposed system can significantly gain machining efficiency without wire breakage hazards.

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Availability of data and materials

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

Code availability

This paper uses proprietary software and will be not available.

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Funding

This research is financially supported by the National Natural Science Foundation of China (Grant No. 52075333) and the National Science and Technology Major Project (2018ZX04005001).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Ling-Yi Xu, Xue-Cheng Xi, Zi-Lun Li, Jie-Yu Ma, Qiang Gao & Wan-Sheng Zhao

  2. State Key Laboratory of Mechanical System and Vibration, Shanghai, 200240, China

    Ling-Yi Xu, Xue-Cheng Xi, Zi-Lun Li, Jie-Yu Ma, Qiang Gao & Wan-Sheng Zhao

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  1. Ling-Yi Xu
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  2. Xue-Cheng Xi
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  3. Zi-Lun Li
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  6. Wan-Sheng Zhao
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Contributions

Lingyi Xu: methodology, platform building, data collection, investigation, writing—original draft preparation. Xuecheng Xi: conceptualization, supervision, writing—reviewing and editing. Zilun Li: platform building. Jieyu Ma: data collection. Qiang Gao: data collection. Wansheng Zhao: supervision, writing—reviewing and editing.

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Correspondence to Xue-Cheng Xi or Wan-Sheng Zhao.

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Xu, LY., Xi, XC., Li, ZL. et al. Wire breakage prevention for reciprocated traveling WEDM based on discharge location detection. Int J Adv Manuf Technol 123, 1859–1875 (2022). https://doi.org/10.1007/s00170-022-10240-0

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