Journal of Applied Mechanical Engineering

Modeling of wire vibration in wire electrical discharge machining process

International Conference on Design and Production Engineering

July 25-26, 2016 Berlin,Germany

Sameh Shawky Habib

Benha University, Egypt

Posters & Accepted Abstracts: J Appl Mech Eng

Abstract:

Wire electrical discharge machining (WEDM) is extensively used in machining of conductive materials when producing precision products. WEDM has higher capability for cutting complex shapes with high precision for very hard materials. During the WEDM process, the wire behaves like a metal string, straightened by two axial pulling forces and deformed laterally by a sum of forces from the discharge process. Major forces acting on the wire can be classified into three categories. The first is a tensile force, pulling the wire from both sides in axial direction and keeping it straight. The second is the dielectric flushing force that comes from circulation of the dielectric fluid in the machining area. The third category consists of forces of different kinds resulting from sparking and discharging. The large amplitude of wire vibration leads to large kerf widths, low shape accuracies, rough machined surfaces, low cutting speeds and high risk of wire breakage. Such tendencies for poor machining performance due to wire instability behavior appear with thinner wires. In this study, direct observation using high-speed camera investigated the movements of tungsten wire electrode during fine wire EDM process. Also, a mathematical model correlating the interactive and higher order influences of various parameters affecting wire vibration during the WEDM process through response surface methodology (RSM) were investigated. The adequacy of the above proposed model has been tested using analysis of variance (ANOVA). Optimal combination of these parameters has been obtained to minimize wire vibration.

Biography :

Email: sameh.abadir@feng.bu.edu.eg