An energy-distribution strategy in fast-cutting wire EDM, wire EDM Filters supplier
Abstract
The technical requirements of fast-cutting wire EDM are revealed in this paper. In addition to high input pulse energy, fast cutting (cutting speed > 200 mm2/min) without damaging the electrode wire needs a high energy efficiency for maintaining a stable fast-cutting process and moderate wire temperature. Based on a synthesis of experimental results and pulse energy analysis, an energy-distribution diagram concerning the correlation between cutting speed and comprehensive machining conditions has been established to determine a suitable parameter combination for a stable fast-cutting process. High power density and high pulse density are found to be two basic requirements for a constant high cutting speed. Harmful energy loss has to be reduced, otherwise the wire temperature becomes too high due to the dissipated heat. According to the energy-distribution diagram, machining conditions such as cutting width, wire diameter and wire traveling speed are also considered in increasing the cutting speed. After an optimization of the energy distribution in fast-cutting wire EDM, a 4-fold improvement in cutting speed has been achieved whilst the wire service life remains almost unchanged. The surface conditions of the cut workpiece are examined through SEM microscopy: the surface roughness is lower than usually expected. A systematic approach is presented for a very fast cutting process. The achievements described here have practical significance in enhancing mold/die productivity as well as in transferring wire EDM into a general cutting alternative. With the cutting speed being increased, the inherent advantages of wire EDM can be used in many cutting cases.
