Study on the machining mechanism of WEDM with ultrasonic vibration of the wire

Abstract WEDM assisted by ultrasonic vibration of the wire has a better machining result than that of wire cut alone. In order to study its machining mechanism, the methods of experiment as well as simulation have been used to verify some hypotheses and interpretation. By means of experiments employing single pulse discharge it has been established that the high frequency vibration of the wire electrode is able to bring about multiple channel discharges so that better surface quality and a high cutting rate can be obtained simultaneously. The simulation of the dynamic characteristics of the wire electrode under the action of continuous discharge forces shows that ultrasonic vibration facilitates the shift of the discharge points and improves their distribution. A set of statistical experiments has been designed to analyzed the utilization of the pulse. It is revealed that with ultrasonic vibration there is a greater utilization of energy, which is a critical factor in securing an increase in the cutting rate.