Experimental Studies on Dry WEDM in Improving Surface Quality

Abstract

This study investigates the dry wire electrical discharge machining (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, pulse interval, peak current, offset, wire winding speed and wire length on roughness, straightness and removal rate had been studied in dry and wet conditions. Experiment results show that multiple cut with dry WEDM in semi-finishing and finishing can improve surface roughness significantly.

Empirical Modeling of High-Speed WEDM Finishing in Gas

“…Although liquid medium is regarded as indispensable for the stability and efficiency of the process, but it may cause certain environmental pollution [5]. WEDM in gas is a newly developed process and an environment-friendly modification of process in which the liquid dielectric is replaced by a gaseous medium [6]. WEDM in gas has lots of advantages, such as excellent straightness, narrow discharge gap, no electrolytic corrosion on surface, non-polluted in the machining processing and so on.…”