Simulation Study On Wire Cutting Temperature Field And Electrode Wire Vibration Of Variable Thickness Workpiece

When EDM wire machining cut workpiece with variable thickness,the evaluation of the machining quality is not only by the roughness requirements of a single thickness workpiece,but also the consistency of the surface roughness of each thickness workpiece is good surface quality,and the processing efficiency is high;at the same time,suppress electrode wire vibration will be beneficial to the processing quality Improved;in the past,WEDM in gas did not have a flowing gas effect.The study found that the application of a gas flow field will affect the processing result,which is also the focus of the study.This paper studies the various boundary conditions required for the simulation of the temperature field of a variable-thickness workpiece,including a moving Gaussian heat source,the radius of the discharge channel,and the latent heat of the material phase change,a temperature field simulation model is established.The boundary conditions required for the simulation of the variable jet gas flow field were determined,including inlet and outlet conditions,wall boundary conditions,etc,and a variable jet fluid model was established.Analyze the cause of the vibration,and establish a transverse vibration model of the electrode wire.The temperature field of the electrode wire and the surface of the workpiece under different electrical parameters were obtained through simulation,and the influence of the peak current and pulse width on the temperature field was further confirmed.The influence of the variable jet gas flow field with the jet angle and jet pressure was analyzed,and the effect of the variable jet on the surface of the workpiece was studied.Perform modal analysis of the electrode wire,and study the effect of tension force and guide wheel span on the natural frequency.Combined with the actual processing to obtain the lateral amplitude of the forced vibration of the electrode wire,the flow field analysis results are introduced to perform afluid-solid coupling analysis of the electrode wire.The effect of the variable jet flow field on the wire vibration was studied.Based on the simulation results of the surface temperature field of the workpiece,a single model of the electro-etched pit is established,the arrangement is determined,and the model of the surface erosion of the workpiece is established.The effects of electrical parameters on the size and volume of the etched pit are analyzed based on the simulation results.The extreme value response surface is used to analyze the significant degree of influence of various factors on the vibration of the electrode wire,and the response surface equation of the frequency and amplitude of the electrode wire vibration is established,which provides a theoretical basis for suppressing the electrode wire vibration.The single-factor method is used to perform rough machining in liquid and finish machining in air for variable thickness workpieces.In the finishing experiment,the single-thickness workpiece was used to study the results of surface quality and erosion changes with parameters at first;secondly,study the combination of parameters that can obtain better consistent processing quality when processing variable-thickness workpieces;Compare experimental and simulated results to verify erosion modelling.