Modeling and Simulation of Wire Electrode Deflection in WEDM

Abstract:

In the process of wire electrical discharge machining, the wire electrode inevitably suffers bending deformation due to wire tension, electrostatic force, electrodynamics force, etc., and the deflection would make an clearly negative impact upon the machining accuracy, productivity and stability. In this paper, first of all, a novel modeling and simulation method is proposed for quantitatively calculating the wire deflection. Secondly, the mainly impact factors and trend of wire deflection have been concluded. Moreover, the feasibility of the model is proved by comparing with other researchers models. Eventually, the practical approaches of reducing wire deflection and improving the machining accuracy have been proposed.

• Periodical: Applied Mechanics and Materials (Volumes 541-542)
• Pages: 708-712
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.541-542.708
• Online since: March 2014
• Authors: Zhi Chen*, He Li, Yu Huang, Zhen Zhang
• Keywords: Machining Accuracy, Model, Simulation, Wire Deflection, Wire Electrical Discharge Machining (WEDM)

References

[1] Puri, A. B., and Bhattacharyya, B. Modelling and analysis of the wire-tool vibration in wire-cut EDM. Journal of materials processing technology 141. 3 (2003): 295-301.

DOI: 10.1016/s0924-0136(03)00280-2

[2] Dauw, D. F., and Beltrami, I. High-precision wire-EDM by online wire positioning control. CIRP Annals-Manufacturing Technology 43. 1 (1994): 193-197.

DOI: 10.1016/s0007-8506(07)62194-5

[3] Beltrami, Ivano, Axel Bertholds, and Dirk Dauw. A simplified post process for wire cut EDM. Journal of materials processing technology 58. 4 (1996): 385-389.

DOI: 10.1016/0924-0136(95)02212-0

[4] Luo, Y. F. Rupture failure and mechanical strength of the electrode wire used in wire EDM. Journal of Materials Processing Technology 94. 2 (1999): 208-215.

DOI: 10.1016/s0924-0136(99)00107-7

[5] Puri, A. B., and Bhattacharyya, B. An analysis and optimization of the geometrical inaccuracy due to wire lag phenomenon in WEDM . International Journal of Machine Tools and Manufacture 43. 2(2003): 151-159.

DOI: 10.1016/s0890-6955(02)00158-x

[6] Han, Fuzhu, Jie Zhang, and Isago Soichiro. Corner error simulation of rough cutting in wire EDM. Precision engineering 31. 4 (2007): 331-336.

DOI: 10.1016/j.precisioneng.2007.01.005

[7] Sanchez, J. A., Plaza, S., Lopez de Lacalle, L. N., and Lamikiz, A. Computer simulation of wire-EDM taper-cutting. International Journal of Computer Integrated Manufacturing 19. 7 (2006): 727-735.

DOI: 10.1080/09511920600628855

[8] Sarkar, S., Sekh, M., Mitra, S., and Bhattacharyya, B. A novel method of determination of wire lag for enhanced profile accuracy in WEDM. Precision Engineering 35. 2 (2011): 339-347.

DOI: 10.1016/j.precisioneng.2011.01.001