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Effect of discharge accumulation on wire breakage in WEDM process

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Abstract

In recent years, WEDM has been adopted in precision machining as an important alternative machining method because of its greater flexibility and lower wear cost compared with traditional machining, whereas wire breakage during WEDM is an unignorable problem that influences the machining quality and efficiency. Therefore, it has been a research topic of considerable interest. This work focuses on exploring the reason for the wire breakage. Firstly, by observing the wire after discharges and using the finite element method, a complete thermal model considering both latent heat and flushing efficiency was built. With this model, the simulation of the crater on the wire was finished. Then based on the result gotten from the simulation and experiment, the heat partition ratio to the wire was found as 46.74% by inverse fitting. After that, a wire breakage experiment was done and through locating the position of 50 discharges before wire breakage it is found that 34% of discharges were located within a range of 2 mm, and the minimum area in the wire cross-section only remained 41.88% compared with the original wire. This kind of decrease in the cross-section area made the stress higher than the UTS of the wire and caused the wire breakage. The findings of this work allow for a more in-depth understanding of the effect of discharge accumulation on wire breakage.

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Funding

This work received funding support from the Spanish Ministry of Economy and Competitiveness and the FEDER operation program for funding the project “Scientific models and machine-tool advanced sensing techniques for efficient machining of precision components of Low-Pressure Turbines” (DPI2017-82239-P).

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Authors and Affiliations

  1. University of the Basque Country (UPV/EHU), Plaza Torres Quevedo 1, 48013, Bilbao, Spain

    Jun Wang, José A. Sánchez & Borja Izquierdo

  2. Aeronautics Advanced Manufacturing Center, CFAA (UPV/EHU), Bizkaia Technology Park, Building 202, 48170, Zamudio, Spain

    Jun Wang, José A. Sánchez & Izaro Ayesta

Authors
  1. Jun Wang
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  2. José A. Sánchez
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  3. Borja Izquierdo
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Jun Wang. The first draft of the manuscript was written by Jun Wang and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Jun Wang.

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Wang, J., Sánchez, J.A., Izquierdo, B. et al. Effect of discharge accumulation on wire breakage in WEDM process. Int J Adv Manuf Technol 125, 1343–1353 (2023). https://doi.org/10.1007/s00170-022-10786-z

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  • DOI: https://doi.org/10.1007/s00170-022-10786-z

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