Dual-axial Ultrasonic Assisted Wire-EDM Process with Vibration Exerted through the Upper Guide

It is difficult for conventional Wire Electrical Discharge Machining (Wire-EDM) to deal with the cutting of a very thick workpiece. The frequent wire-breakage resulting in wire scratches and severe time-cost, and even the inevitable drum-shaped remained on the lateral wall of workpiece also caused p...

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Bibliographic Details
Published inProcedia CIRP Vol. 95; pp. 319 - 324
Main Authors Hsue, Albert Wen-Jeng, Su, Zih-Siou, Lin, Yang-Lei
Format Journal Article
LanguageEnglish
Published Elsevier B.V 2020
Subjects
Dual-axial
DUV-WEDM
Elliptical Expansion
Stability
Ultrasonic
Wire-EDM
Dual-axial
Elliptical Expansion
DUV-WEDM
Stability
Ultrasonic
Wire-EDM
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Summary:It is difficult for conventional Wire Electrical Discharge Machining (Wire-EDM) to deal with the cutting of a very thick workpiece. The frequent wire-breakage resulting in wire scratches and severe time-cost, and even the inevitable drum-shaped remained on the lateral wall of workpiece also caused problems to the finishing. Although there was ultrasonic vibration-assisted Wire-EDM reported in the past, they were conducted by only one axial vibrator causing an elliptical expansion in that vibration direction. In this paper, a novel dual-axial ultrasonic vibration (DUV-WEDM) with phases difference of 90o along the orthogonal direction is proposed to prevent the wire from breakage and the elliptical expansion. The module is implemented among the upper guide and the top of workpiece, driven by two ultrasonic actuators and a dual-channel signal source. Because of the dispersion of sparks location and increase of stability index, the proposed strategy benefits from reducing the risk of wire-rupture significantly in comparison with the conventional Wire-EDM. Besides, it improves the cutting accuracy simultaneously because of the uniform EDM expansion by the circular trajectory compared to the single axial vibration mode. Moreover, even the drum-shapedd along the lateral wall is more flattened than conventional cutting by the DUV-WEDM module.
ISSN:2212-8271
2212-8271
DOI:10.1016/j.procir.2020.02.262