DEVELOPMENT OF SIMULATION
SYSTEM ON WEDM FIRST CUT

HAN Fuzhu¹  TAO Chunsheng²  ZHOU Xiaoguang²  MASANORI Kunieda³

(1. Department of Precision Instruments & Mechanology, Tsinghua University, Beijing 100084;

2. School of Automation, Beijing University of Posts and Telecommunications, Beijing 100876;

3. Department of Mechanical Systems Engineering, Tokyo University of Agriculture & Technology,Tokyo 1848588 Japan)

Abstract: In order to understand the mechanism of WEDM (Wire electrical discharge machining) and find out the influence of machining parameters on the accuracy, a simulation system for WEDM is developed., which can accurately reproduce the discharge phenomena of WEDM machining on computer through searching for the discharge location, removing the workpiece and analyzing wire vibration. To verify the feasibility of the simulation system, the simulation results are compared with the experimental results. In order to obtain the 3D data of the discharge gap and workpiece shape from the experimental results, a new measurement is proposed. By comparing the simulation results and experimental results, it is found that the simulation method is feasible. The results show that the machined shape obtained from the simulation is almost consistent with the machined shape obtained from the experiments when the wire tension and servo voltage are adjusted; whether the machined shape along machining direction is convex feature or concave feature depends on the relative value between the explosive force and electrostatic force. 

Key words: WEDM  Simulation  First cut  Discharger location

CLC No: TG661

国家973计划(2003CB716204)和国际合作课题(0405J33)资助项目. Received 20051013, received in revised form 20060309