Influence of the main technological parameters and material properties of the workpiece on the geometrical accuracy of the machined surface at wedm

Geometrical accuracy is currently one of the important parameters regarding the machined surfaces of components used in modern technical equipment. Even though the WEDM technology belongs to the precise final machining technologies, the most demanding requirements for the geometrical accuracy of the machined surface are not always met. These geometrical deviations consequently manifest themselves not only in the assembly of particular parts of the final product but also in their operation. In addition, errors of the geometrical accuracy of the machined surface also have negative effect on the serviceability of the finished parts and their overall service life. Even though these shortcomings are only minimally reflected in planar cuts, the production of circular profiles is a problem in particular. The important factors causing this poor quality are the technological parameters in combination with the specific physical and mechanical properties of the workpiece and wire electrode. Experimental research was therefore focused on identifying the influence of selected technological parameters and material properties of the workpiece on the size of geometrical deviations of the machined surface that occur at WEDM using CuZn37 wire electrode. In general, it is also a serious problem to maintain the prescribed geometrical tolerance of the machined surface in a narrow tolerance field. By exceeding it, the product becomes unsatisfactory. However, the problem is also achieved quality, which significantly exceeds the expected values. This essentially reduces productivity and worsens the economic efficiency of production. For this reason, it is ideal to achieve the exact required quality of the machined surface in terms of geometrical accuracy. Therefore, an algorithm of simulation software was proposed, which includes empirically determined mathematical models, based on which the software can predict the necessary setting of technological parameters, derived from the dimensional and material properties of the workpiece and wire. The mentioned solution thus will bring the geometrical accuracy of the production of circular holes in a narrow tolerance field to the customer’s requirements with a significant increase of the economic efficiency of production.

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