Study of wire breaking process and monitoring of WEDM
Resource
International Journal of Machine Tools and Manufacture 37 (4): 555-567
Journal
International Journal of Machine Tools and Manufacture
Journal Volume
37
Journal Issue
4
Pages
555-567
Date Issued
1997
Date
1997
Author(s)
Liao, Y. S.
Chu, Y. Y.
Yan, M. T.
Abstract
Wire rupture in the Wire Electrical Discharge Machining (WEDM) process is a serious problem to manufacturers. A new computer-aided pulse discrimination system based on the characteristics of voltage waveform during machining was developed in this paper. With the use of this system, a large amount of sparking frequency data during wire rupture process and under normal working conditions were collected and analyzed. Two symptoms of wire rupture were identified: the excess of arc sparks, and a sudden rise of the total sparking frequency. The governing mechanisms of these two types of wire rupture were found from the SEM and EDAX analyses of the ruptured wire electrode. Furthermore, an index to monitor wire breaking was identified, and its relationships with the metal removal rate and machining parameters were found. Based on the results obtained in the paper, a control strategy to prevent wire from rupturing while at the same time improving the machining speed is proposed. © 1997 Published by Elsevier Science Ltd. All rights reserved.
Other Subjects
Adaptive control systems; Computer aided analysis; Electric sparks; Frequencies; Speed; Temperature; Thermal effects; Wire; Breaking; Wire electrical discharge machining; Wire rupture; Machining
Type
journal article
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