Adjustment of Wire Vibrations in Order to Improve Geometric Accuracy and Surface Roughness at WEDM

Abstract

Although WEDM is one of the most precise finishing technologies, deviations from the required geometric shapes and surface roughness occur in the production of parts with rotary surfaces. Even though these shortcomings have only a minimal impact on planar cuts, the production of circular profiles is a different problem. One of the factors causing this poor quality is the vibration of the wire electrode. With appropriate vibration adjustment, it would be possible to achieve significant improvements of the eroded area quality, both in terms of geometric accuracy and in terms of surface roughness. This would significantly increase quality, enabling WEDM technology to compete with other technologies in terms of economic efficiency. Therefore, the proposed solution aims to provide a partial adjustment to the wire tool electrode vibrations, based on their sensing by the means of acoustic emissions or a laser beam, with subsequent dynamic adjustment of the actual technological parameter values. This way, the given solution will increase the production accuracy of circular holes, increase productivity, and ultimately provide an overall increase in the economic efficiency of the WEDM process. The article also presents the scheme of a control algorithm for monitoring and subsequent adjustments of the vibrations of the wire tool electrode during the electroerosion process in order to minimize geometric deviations of circularity, cylindricity and roughness of the machined surface.

Efficiency of the Machining Process of Circular Shapes by Electrical Discharge Technology

“…Therefore, a detailed preparation of the experiment based on a thorough preliminary analysis of the current state of the field should be carried out. For this reason, a detailed search of the current state of the subject was carried out based on the research carried out so far by renowned authors dealing with the subject [13][14][15][16][17][18][19][20][21]. Only then was it proceeded to the realization of experiments based on a detailed defined database of input data necessary for their realization.…”

Surface Quality of Carbide Metal After Electrical Discharge Machining

“…Electrical discharge machining can generally be characterized as a machining process that is based on the electrical discharge principle [13]. It is carried out between the tool electrode and the work material using precisely controlled, cyclically repeating electrical discharges in the presence of a dielectric [14,15]. Since the whole machining process is carried out in a force-free manner, it finds its suitable application also in the machining of hard metals [16,17].…”