Analysis Of Discharge State As Well As Elements And Size Distribution Of Debris In The Processing Of Wire-EDM

Wire EDM is an advanced processing method used primarily for the manufacture of high value-added parts for aerospace,high-precision tools and biomedical implants.Although the process is very common in industrial applications in developed countries,the scientific principles of the process are less analyzed.The development of next-generation machine tools requires a deeper understanding of this process.The study of the actual situation of the discharge gap is one of the hot issues in this field.It is well known that the gap width and the presence of processed particles are the main factors affecting the dielectric breakdown strength,and the dielectric breakdown strength is the main cause of the discharge.At present,many research work in the field of EDM focuses on the study of debris characteristics of sinking EDM.However,there is almost no literature available in the field of online cutting processing because it is difficult to obtain factors such as the situation in the gap between the real electrodes and the vibration of the wires.This study focuses on two scientific foundations in the process of EDM.The first aspect is the discharge pulse analysis.Each process consists of countless discharges.The state of each discharge pulse directly affects the surface finish quality.First,the discharge signal during processing is collected.The discharge signal is composed of the voltage and current signals between the anode and the cathode,and then the program is programmed and the discharge state is analyzed.This study attempts to find the effect of current and disconnection on the type of discharge pulse in actual machining.To this end,a series of experiments were carried out,the signal was collected by an oscilloscope,and then the program was programmed with MATLAB software to further statistically analyze the discharge pulse state.On the other hand,the element composition,morphology and size distribution of the particles during the wire cutting process are analyzed.In this work,a device for collecting particles and cutting fluid from the work area was designed and fabricated,and particles were collected under different processing parameters.In the process of obtaining the elemental composition,shape and size distribution of the particles,techniques such as X-ray fluorescence spectrometer,laser diffraction particle size analyzer,electron scanning microscopy and electron transmission microscopy are used to measure the fragments generated during the wire cutting process.Overall goal:Based on the above research results,analyze the relationship between process parameters;and try to find the trend between WEDM discharge state statistics and debris size distribution.These conclusions will contribute to the establishment of thermal models of particle motion and electric field in the WEDM working gap in the future.