Optimization of machining parameters and wire vibration in wire electrical discharge machining process

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• 作者：Sameh Habib
• 关键词：Wire electrical discharge machining (WEDM) ; Mathematical modeling ; Wire vibration ; Kerf width and response surface methodology (RSM)
• 刊名：Mechanics of Advanced Materials and Modern Processes
• 出版年：2017
• 出版时间：December 2017
• 年：2017
• 卷：3
• 期：1
• 全文大小：1149KB
• 刊物类别：Theoretical and Applied Mechanics; Structural Materials; Computational Science and Engineering;
• 刊物主题：Theoretical and Applied Mechanics; Structural Materials; Computational Science and Engineering;
• 出版者：Springer International Publishing
• ISSN：2198-7874
• 卷排序：3

文摘

BackgroundWire Electrical discharge machining (WEDM) has higher capability for cutting complex shapes with high precision for very hard materials without using high cost of cutting tools. During the WEDM process, the wire behaves like a metal string, straightened by two axial pulling forces and deformed laterally by a sum of forces from the discharge process. Major forces acting on the wire can be classified into three categories. The first is a tensile force, pulling the wire from both sides in axial direction and keeping it straight. The second is the dielectric flushing force that comes from circulation of the dielectric fluid in the machining area. The third category consists of forces of different kinds resulting from sparking and discharging. Large amplitude of wire vibration leads to large kerf widths, low shape accuracies, rough machined surfaces, low cutting speeds and high risk of wire breakage. Such tendencies for poor machining performance due to wire instability behavior appear with thinner wires.