Advertisement

Interelectrode discharge mechanism in high-speed wire electrical discharge machining

  • Zhang Yueqin
    • 1
    • 2
  • Liu Zhidong
    • 1
  • Xia Lixia
    • 1
  • Wang Wei
    • 1
  1. 1.College of Mechanical and Electrical EngineeringNanjing University of Aeronautics and AstronauticsNanjingChina
  2. 2.Jincheng College of Nanjing University of Aeronautics and AstronauticsNanjingChina
ORIGINAL ARTICLE
First Online: 05 October 2015
Received:
Accepted:

Abstract

Different from conventional electrical discharge machining (EDM), given that the dielectric fluid utilized in high-speed wire EDM (HSWEDM) has a certain conductivity, a passive film can form on the workpiece surface because of the electrochemical reaction during processing. Such formation affects the interelectrode discharge characteristics. The formation mechanism of the passive film was analyzed in this study. The effect of the passive film on the discharge gap was evaluated through single-pulse discharge experiments. Results show that the density and thickness of the passive film increase with the increase in dielectric fluid conductivity or the accumulation of leakage energy; the discharge gap is thus reduced. However, in actual processing, the existence probability of open-circuit voltages is very small, and the high temperature produced by spark discharge has an erosion effect on the passive film. Consequently, forming a dense passive film on a workpiece surface is difficult, and spark discharge still occurs in an interelectrode gap in HSWEDM. A multi-cutting experiment was conducted to study the effect of the passive film on dimensional accuracy. Results indicate that the passive film affects the discharge gap because of the difference in dielectric fluid conductivity. A size error of approximately 2 μm was generated when the initial conductivity difference was roughly 2000 μS/cm.

Keywords

HSWEDM Interelectrode discharge Passive film Discharge mechanism 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Ho KH, Newman ST, Rahimifard S, Allen RD (2004) State of the art in wire electrical discharge machining (WEDM). Int J Mach Tools Manuf 44:1247–1259CrossRefGoogle Scholar
  2. 2.
    Kwon S, Lee S, Yang MY (2015) Experimental investigation of the real-time micro-control of the WEDM process. Int J Adv Manuf Technol 79:1483–1492CrossRefGoogle Scholar
  3. 3.
    Mahapatra SS, Patnaik A (2007) Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method. Int J Adv Manuf Technol 34:911–925CrossRefGoogle Scholar
  4. 4.
    Yuan J, Wang KS, Yu T, Fang ML (2008) Reliable multi-objective optimization of high-speed WEDM process based on Gaussian process regression. Int J Mach Tools Manuf 48(1):47–60CrossRefGoogle Scholar
  5. 5.
    Liu ZD, Gao CS (2011) Electrical discharge machining technology and application. China Machine Press, BeijingGoogle Scholar
  6. 6.
    Liu JC, Bai JC, Guo YF (2008) Non-traditional machining. China Machine Press, BeijingGoogle Scholar
  7. 7.
    Chen LJ, Zhang ZY, Huang YH, Zhao GG (1985) Research on discharge status and tension of wire electrode in WEDM. Electromachining 4:5–10Google Scholar
  8. 8.
    Liu ZD, Zhang Y, Wang ZX, Xu AY (2010) Research on discharge mechanism and correction value of multi-cutting based on composite cooling liquid. China Mech Eng 21(24):2925–2928Google Scholar
  9. 9.
    Guo ZN, Pan ZC, Wang CY, Tang ZQ (1994) Study on electrochemical effect in WEDM-HS. Adv Intell Prod. 619–623Google Scholar
  10. 10.
    Liu ZD (2005) Research on the general feature of emulations and dielectrics and its tendency in WEDM-HS. Aviat Precis Manuf Technol 41(3):38–41Google Scholar
  11. 11.
    Chen ZQ, Li MH (1979) Interelectrode colloid system in electrical discharge machining. Electromachining 5:1–9Google Scholar
  12. 12.
    Chakraborty S, Dey V, Ghosh SK (2015) A review on the use of dielectric fluids and their effects in electrical discharge machining characteristics. Precis Eng 40:1–6CrossRefGoogle Scholar
  13. 13.
    Li MH, Yang XX (2010) Numerical control wire electrical discharge machining processing technology and application. National Defense Industry Press, BeijingGoogle Scholar
  14. 14.
    Wang XZ, Liu ZD, Xue RY, Tian ZJ, Huang YH (2014) Research on the influence of dielectric characteristics on the EDM of titanium alloy. Int J Adv Manuf Technol 72(5–8):979–987CrossRefGoogle Scholar
  15. 15.
    Tosun N (2003) The effect of the cutting parameters on performance of WEDM. KSME Int J 17(6):816–824Google Scholar
  16. 16.
    Liu ZD, Wei W, Lu LY, Xu AY (2012) Research of relationship between interelectrode dielectric properties and energy distribution in wire electrical discharge machining. J Shanghai Jiaotong Univ 46(7):1015–1020Google Scholar
  17. 17.
    Li MH (1989) Theoretical foundation of electrical discharge machining. National Defense of Industry Press, BeijingGoogle Scholar
  18. 18.
    Qiu MB, Liu ZD, Tian ZJ, Wang W, Huang YH (2013) Study of unidirectional conductivity on the electrical discharge machining of semiconductor crystals. Precis Eng 37(4):902–907CrossRefGoogle Scholar
  19. 19.
    Albinski K, Musiol K, Miernikiewicz A, Labuz S, Malota M (1996) The temperature of a plasma used in electrical discharge machining. Plasma Sources Sci Technol 5:736–742CrossRefGoogle Scholar
  20. 20.
    Weingärtner E, Wegener K, Kuster F (2013) Influence of workpiece circumferential speed in wire electrical discharge machining. Procedia CIRP 6:238–243CrossRefGoogle Scholar
  21. 21.
    Xia LX, Liu ZD, Li MM, Wang W (2014) Research on the detection and mechanism of dielectric fluid’s life in HSWEDM. Electromachining Mould 6:21–24Google Scholar
  22. 22.
    Huang JT, Liao YS, Hsue WJ (1999) Determination of finish-cutting operation number and machining-parameters setting in wire electrical discharge machining. J Mater Process Technol 87:69–81CrossRefGoogle Scholar
  23. 23.
    Zhang GJ, Zhang Z, Ming WY, Guo JW, Huang Y, Shao XY (2014) The multi-objective optimization of medium-speed WEDM process parameters for machining SKD11 steel by the hybrid method of RSM and NSGA-II. Int J Adv Manuf Technol 70:2097–2109CrossRefGoogle Scholar
  24. 24.
    Liu ZD, Yu RH (2007) Realization of multi-cutting in WEDM-HS. China Mech Eng 18(20):2410–2413Google Scholar
  25. 25.
    Li MQ, Li MH, Xu GY (2005) Study on the variations of form and position of the wire electrode in WEDM-HS. Int J Adv Manuf Technol 25(9–10):929–934Google Scholar
  26. 26.
    Xiong GY, Zheng MZ, Li DY, Zhao LZ, Wang YL, Li MH (2010) Study on the influence of non-electrical parameters on processing quality of WEDM-HS and improvement measures. Comput Computing TechnolAgric IV-IFIP TC 12:514–520Google Scholar

Copyright information

© Springer-Verlag London 2015

Personalised recommendations