The Device Development And Cutting Process Test Of Stranded-electrode Wire Of High-speed WEDM

In the process of large energy and large thickness cutting of high-speed WEDM,the efficiency of machining is difficult to be improved due to the shortage of working fluid and the timely removal of corrosion products,a new type of electrode wire,twisted wire,is proposed in this paper.The fabrication device of the twisted electrode wire is based on the single electrode wire to twist the double twisted electrode wire.The stranded electrode wire is applied to the machining of large energy and large thickness of high-speed WEDM,which solves the problems of the difficulty of the liquid and chip removal of the conventional electrode wire,it has important application value for improving the cutting efficiency of the WEDM under the condition of large energy and large thickness.The major research works are as follows:(1)The scheme of the twisted electrode wire device was proposed and the whole device was modularized.It can solve the key problems,such as back twisting of single electrode wire,constant tension control and uniform wire receiving.And also solves the problem of the regular compact wire winding of different wire diameters of stranded electrode wires.(2)The twisted-wire module,the wire-collecting module,the parts of the frame were designed concretely.The devices including inverter and photoelectric switch used in the control system were introduced,and the working principle of the whole control system was given.The twisted electrode wire device is fabricated and the stranded electrode wire was successfully twisted.A new synchronous belt pulley and synchronous belt were designed to increase the wire spacing of the machine tool which can avoid the stacking phenomenon of the stranded electrode wire with coarse wire diameter.(3)The experimental law of the cutting process of the twisted wire was studied.Under the conditions of different discharge energy,the comparison experiment between the twisted electrode wire and the circular cross section electrode wire is made,it is found that twisted electrode wire has better ability to take in working fluid to the inter-electrode and remove corrosion products out of the inter-electrode than the circular cross section electrode wire,so that the inter-electrode can be fully cooled and deionization.Therefore,the cutting efficiency of the twisted electrode wire is higher,the workpiece has better surface quality,and the advantage of the wire electrode is more obvious with the increase of energy.Because the volume of helical grooves of the same length of twisted wire is inversely proportional to the distance of the twist.The larger the volume of the spiral grooves is,the stronger the ability of liquid and chip removal is,the better the processability is.(4)Study on the comparison test on the machining of workpiece with different thickness with twisted electrode wire and circular section electrode wire,it is found that with the increase of the thickness of the workpiece,the ability of the liquid and chip removal of the twisted electrode wire is gradually manifested.Therefore,the cutting speed of the twisted electrode wire is more than that of the circular section electrode wire.