Research On Super-high Thickness Machining Technology Of HSWEDM

High speed wire electrical discharge machining(HS-WEDM)is the original mode of WEDM in China.It has been widely applied in the field of aerospace,automobile manufacturing,and complex and irregular hard machining materials.Compared with LS-WEDM,HS-WEDM has an irreplaceable advantage in cutting large taper and high thickness workpiece.However,HS-WEDM is difficult to cutting the workpiece that is more than 1000 mm,and it has some problems such as low efficiency and stability,and uneven cutting surface.As for the questions above,we carried out a systematic research about Super-high Thickness High-Speed Wire Electrical Discharge Machining.The specific research contents are as follows:(1)The wire guide and tension mechanism of the existing HS-WEDM have been improved,which has played a positive role in the highly efficient and stable machining of super-high thickness workpiece.(2)Through the establishment of the corresponding models,the factors that influence the inter-electrode energy and the Inter-electrode flow field of the super-high thickness workpiece are analyzed.The conclusions are as follows:(a)When the workpiece is thicker,the machining efficiency improves slowly because of the great loss of energy between the two electrodes.As a result,for continuous and efficient super-high thickness workpiece processing,it is necessary to appropriately increase the processing energy.(b)The shear flow is not affected by the length of the parallel plate.Increasing the velocity of the parallel plate and reducing the width of the gap increase shear flow in the gap.(3)The servo control mode,the working fluid and the wire electrode was improved: By improving the servo control mode of existing machine tools,the process can be carried out efficiently and stably;By using the improved dielectric fluid,the machining efficiency and stability were significantly improved and resulted in a better workpiece cutting surface;The new wire electrode can be more efficient and stable to process super-high thickness workpiece.(4)A lot of process experiments are performed.The experimental results show that the process can be carried out efficiently and stably and the workpiece surface can be cut smoothly using the improved working liquid,wire electrode,servo control mode and the devices improved in this paper.