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Nonlinear dynamics analysis of multi-cutting wire electrode in WEDM-HS subjected to working fluid considering the effect of debris

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Abstract

A reasonable dielectric fluid velocity and better exclusion of debris are very important to obtain a stable machining performance in multi-cutting of WEDM-HS. We investigated the dynamic characteristics of multi-cutting wire electrode in WEDM-HS subjected to working fluid considering the effect of debris. First, a fluid-solid coupling nonlinear vibration model is derived by analyzing the forces acting on the multi-cutting wire which locate in the dielectric fluid. The additional axial force arising from the transverse vibration of the multi-cutting wire is considered as a nonlinear term in the model. Considering that the debris accumulation in discharge gap severely influences the stability of multi-cutting wire electrode, the relationship between the debris volume concentration and debris-working fluid two-phase flow drag coefficient is obtained using the Einstein two-phase flow viscosity theory. Finally, the influences of several parameters on the multi-cutting wire displacement are discussed in detail.

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Authors and Affiliations

  1. School of Mechanical Engineering, Jiangnan University, No.1800 Lihu Rd, Wuxi, 214122, Jiangsu Province, China

    Sheng-yao Fan, Qiu-ju Zhang & Hai-wei Chen

  2. Wuxi Institute of Technology, No.1600 Western Gaolang Rd., Wuxi, 214121, Jiangsu Province, China

    Sheng-yao Fan & Wen-xuan Zeng

Authors
  1. Sheng-yao Fan
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  2. Qiu-ju Zhang
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  3. Hai-wei Chen
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  4. Wen-xuan Zeng
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Corresponding author

Correspondence to Qiu-ju Zhang.

Additional information

Recommended by Associate Editor Cheolung Cheong

Sheng-Yao Fan, is currently a Ph.D. candidate at the School of Mechanical Engineering, Jiangnan University, China. His research interests include stability analysis and vibration control; finite element modeling and design; nonlinear dynamical systems; computer-aided design and manufacturing.

Qiu-Ju Zhang, Ph.D., is currently a professor and Ph.D. advisor at the School of Mechanical Engineering, Jiangnan University, China. Her research interests include mechanical dynamics analysis and optimization design; computer-aided design and manufacturing; numerical control and robot technology.

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Fan, Sy., Zhang, Qj., Chen, Hw. et al. Nonlinear dynamics analysis of multi-cutting wire electrode in WEDM-HS subjected to working fluid considering the effect of debris. J Mech Sci Technol 27, 3595–3605 (2013). https://doi.org/10.1007/s12206-013-0902-4

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  • DOI: https://doi.org/10.1007/s12206-013-0902-4

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