This paper studies the surface quality of mould steel with high-speed wire electrical discharge machining (WEDM) method, which is conducted in gas to improve the accuracy of finish cut, and compares the surface quality in atmosphere and in emulsion dielectric. Experiment results showed that WEDM in atmosphere offers advantages such as better surface roughness and higher material removal rate. The relationship about winding speed and worktable feed on WEDMed surface quality in semi-finishing cut and finishing cut had been obtained. Morover, a new attemption was successful in applying dry WEDM in multiple cut to improve surface roughness.
Authors have presented a new procedure as gas-liquid combined multiple cut. In order to acquire the best machining quality and the greatest efficiency, it is necessary to analyze the WEDM process with multiple performance characteristics including machining time and surface roughness and to optimize some processing parameters such as pulse duration, pulse interval, peak current, main power supply voltage, servo feed, offset and servo voltage. The orthogonal experiment is designed to reveal the relationship among the parameters, the gray relevance theory is used to optimize the processing parameters under the multiple process index of the LS-WEDM in gas, namely optimizing the process parameters under the surface roughness and machining time, and the optimized process parameters can be obtained from gray relation grade.
This paper aims at getting the finishing process models in HS-WEDM in gas. Using cutting speed and the roughnessRaas index, the five factors of pulse-on time, peak current, offset, pulse interval ratio and worktable feed were chosen in dry finishing. The effects of the five factors and their interaction on cutting speed and the Surface roughnessRaand empirical models for cutting speed and roughnessRawere developed by performing a designed experiment based on the central composite design (CCD) experiments, significant order influencing cutting speed and roughness were found. The results of the verification test show thatRaRegression Model and Cutting Speed Regression Model have high reliability, and can achieve significant prediction effect, more accurate mathematical models are provided for the further HS-WEDM process research.
Utilizing gas as the dielectric instead of dielectric liquid has enabled the development of dry wire electrical discharge machining (dry WEDM) technology for finishing cut. Experiment results showed that Low-Speed WEDM (LS-WEDM) in gas offers advantages such as better straightness, and shorter discharge gap. This paper studies on influence of different gas dielectrics, wire winding speed and pulse duration on the WEDMed surface quality (discharge gap, straightness, surface roughness, removal rate) in finishing. New attempt of applying dry WEDM as the 4th cut had been proved feasible in improving conventional multiple cut surface quality of LS-WEDM.
This study investigates the dry WEDM in multiple cut. To improve surface quality with high-speed WEDM (HS-WEDM), a new procedure as Gas-liquid Combined Multiple Cut (roughing is processed in dielectric liquid, and semi-finishing is in liquid or gas, while the finishing is in gas) is presented. Effects of pulse duration, peak current, offset, worktable feed and wire length on roughness and removal rate for dry semi-finishing were studied were studied with L16(45) design, and significant order inflluncing roughness and removal rate were found. Experiment results show that multiple cut with dry WEDM in semi-finishing and finishing can improve surface roughness significantly.
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