Experiment Study On Thin Plate Wire Electrical Discharge Machining In Steam Water Mist Medium

In recent years,in the fields of aerospace,communications,machinery,etc,a large number of thin plate parts are required,which affect and determine the performance of the whole device,and Wire Electrical Discharge Machining technology uses the high temperature thermal effect to removal the workpiece,which has a stable process effect and higher processing efficiency is widely used in many fields,and is an irreplaceable processing method.Different processing medium and processing parameters will affect the inter-electrode discharge during the wire cutting process,resulting in differences in quality and efficiency.The backwardness in various aspects of research will severely restrict the development and application of WEDM technology.Development of thin plates in steam water mist medium WEDM experiment research,exploring the characteristics of inter-electrode discharge in water mist and the influence of various factors on the process index,has important practical significance for raise the processing speed and quality of thin plate wire cutting,and improving the processing technology of thin plate cutting.This paper systematically analyzes the conductance and breakdown mechanisms in gaseous medium and water mist medium,as well as the microscopic mechanisms of material removal by electric spark discharge in water mist,The presence of fog droplets can reduce the breakdown voltage between the poles,improve the discharge characteristics between the poles,and select the appropriate water mist particle size and concentration,which can improve the efficiency of the erosion during the processing;and theoretically analyzes the errors in corner cutting,establish a mathematical model of the hysteresis deflection of the electrode wire;the discharge angle and discharge circle are introduced,to analyzes the transient change of the deflection hysteresis of the electrode wire at the corners,which lays the foundation for subsequent related research work.The processing characteristics of the first cutting of WEDM for thin plates in different medium such as emulsion,steam water mist,ultrasonic water mist,and the atmosphere were systematically studied,analysis of different processing medium discharge gap,surface roughness,cutting speed,material removal rate,surface microscopic morphology and surface component energy spectrum and other process index;The study found that the discharge gap in the steam water mist medium is smaller than that in the emulsion,which helps to improve the shape and position accuracy of the workpiece;its surface roughness is superior to the emulsion and the atmosphere;the other indicators are between the emulsion and the atmosphere Both are better than ultrasonic water mist,so the steam water mist medium is used for the subsequent experimental study of thin plate cutting.The use of single-factor experiment method,to study the influence of the parameters of the first cutting of the thin plate wire EDM in steam water mist medium on the process index,and to provide a reference for factor level values for subsequent design of the test plan.The BBD multi-factor experiment method in response surface analysis method,was used to deeply study the processing characteristics of thin plates WEDM in steam water mist medium,to establish a response surface regression model of surface roughness,cutting speed,and discharge gap.Through confidence analysis and credibility analysis,the validity and credibility of the model are verified;analysis of variance and significance test are performed to obtain the order and significance of the primary and secondary effects of each processing parameter and its interaction on each process index;use the response surface analysis method optimizes the best combination of processing parameters,which provides a strong basis for the parameter preferred selection of thin-plate WEDM processing technology.Finally,the corner cutting experiments of thin plates in steam and water mist medium were conducted.The microscopic fillet radius of the internal corne and external corner angles at five angles of 30 °,60 °,90 °,120 °,and 150 ° were used as process evaluation index to analyze the processing characteristics of corner cutting,in order to obtain the influence rule of the thin plate thickness,worktable feed speed,the discharge energy on the corner error;the experimental comparison of three different corner trajectory path compensations is made,and a reasonable machining strategy is proposed,so as to obtain better corner machining quality andachieve the purpose of improving the corner shape accuracy.