Discharge State And Experimental Study Of WEDM For Variable Thickness Workpieces In Steam Mist

Compared with the wire EDM processing in the traditional water-based working fluid,the wire EDM process under multi-media and multiple cutting can effectively improve the process accuracy and obtain better surface roughness,which provides a new practice method for wire EDM processing of workpieces with variable thickness.The use of steam water mist as the processing medium,compared with the processing in liquid,its physical properties and chemical properties are different,so it is necessary to study the processing mechanism and discharge process characteristics of the wire EDM of these two dielectrics.When cutting workpieces of different thicknesses,the change of workpiece thickness will seriously affect the gap discharge state and the quality of the processed workpiece,and the stable maintenance of the discharge state is the guarantee of reliable process,so the establishment of the discharge state detection system is very critical,which has a significant role in the preferred process parameters of the second steam water mist EDM wire cutting.Through in-depth study of the characteristics of multi-media wire cutting processing technology such as working fluid and water mist medium,abnormal spark discharge states such as normal spark discharge,open circuit and short circuit are obtained,and a thickness identification model is established based on the energy relationship of discharge pulse,and the threshold processing of the electrical signal waveform of each discharge state is carried out,and the adaptive algorithm Adam algorithm is used for independent training and learning,and the identification and classification of normal and abnormal discharge states are completed,so as to prepare for the construction and experiment of intelligent detection system.Through LabVIEW software combined with adaptive algorithm to establish the whole system comprehensive detection platform,according to its own experimental working environment and workpiece processing requirements to design the corresponding functional area and select the corresponding electronic components,to achieve the identification of the thickness of the workpiece and the detection of the discharge state in the process of wire cutting processing,and set the voltage early warning module to prevent abnormal situations in the processing process,carry out effective early warning,and ensure the safe and effective progress of the processing process;The integrated detection system is applied to the wire EDM processing experiment,and the first cutting is completed in the water-based working fluid first,so that the roughness of the evaluation index is kept within the normal range;Secondly,the second processing is completed in steam water mist to obtain good surface consistency and roughness,and the regression equation of roughness and related processing parameters is obtained through two modeling and analysis,on the one hand,the optimal processing parameters of each thickness interval are obtained,and on the other hand,the roughness value can be predicted through the regression equation.Finally,the experimental verification of optimized processing parameters is carried out,and the experimental results show that the optimized parameters can ensure better surface roughness and consistency during processing.