Research On Mechanism And Experi-Ments Of Wire Electrode Wear In Wedm

As the fastest developing and the most widely used branch of EDM, WEDM has played an important role in many areas. In the process of WEDM, there is wire electrode wear, which not only affects the machining accuracy, but also has the risk of wire breaking because of the excessive wear of the wire electrode. Due to its unique and complexity of processing mechanism, there is no mature theory to explain the phenomenon. Thereby, the experimental study of wire electrode wear mechanism will not only improve the mechanism of WEDM, but also guide the actual production process to ensure the accuracy and processing efficiency which has an important practical significance.In this thesis, based on extensive literature, the microscopic mechanism of WEDM, the mobile of the discharge channel and the factors of wire electrode wear were analyzed. Considering the thermal convection, temperature-dependent parameters and the discharge channel movement under the influence of heat source by Gaussian, thermodynamic process models have been set up. Using ANSYS software, the temperature field simulation has been done to analyze the ratio of peak current and pulse width and current rising slope.The experiments of the wire electrode wear based on the switch controlled power and current waveforms controlled power have been done and drew up a more reasonable machining path. Make use of transient response method to analyze the current waveform controlled power supply to explain the phenomenon that the current rising slope changed a little due to the increase of the inductor value. It shows that the main factor of wire electrode wear is the rising of current slope, followed by the ratio of peak current and pulse width and peak current. According to the above conclusions, in the small current increase in slope, low ratio of peak current and pulse width, small peak current and processing speed reduction, the electrode wire will wear less than 5μm when cutting 105 mm2.