Effect of discharge accumulation on wire breakage in WEDM process

In recent years, WEDM has been adopted in precision machining as an important alternative machining method because of its greater flexibility and lower wear cost compared with traditional machining, whereas wire breakage during WEDM is an unignorable problem that influences the machining quality and...

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Detalhes bibliográficos
Autores: Wang, Jun, Sánchez Galíndez, José Antonio, Izquierdo Aramburu, Borja, Ayesta Rementeria, Izaro
Formato: artículo
Fecha de publicación:2023
País:España
Recursos:Universidad del País Vasco
Repositorio:Addi. Archivo Digital para la Docencia y la Investigación
OAI Identifier:oai:addi.ehu.eus:10810/72272
Acesso em linha:http://hdl.handle.net/10810/72272
Access Level:acceso abierto
Palavra-chave:WEDM
wire breakage
heat partition
thermal model
discharge location
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spelling Effect of discharge accumulation on wire breakage in WEDM processWang, JunSánchez Galíndez, José AntonioIzquierdo Aramburu, BorjaAyesta Rementeria, IzaroWEDMwire breakageheat partitionthermal modeldischarge locationIn recent years, WEDM has been adopted in precision machining as an important alternative machining method because of its greater flexibility and lower wear cost compared with traditional machining, whereas wire breakage during WEDM is an unignorable problem that influences the machining quality and efficiency. Therefore, it has been a research topic of considerable interest. This work focuses on exploring the reason for the wire breakage. Firstly, by observing the wire after discharges and using the finite element method, a complete thermal model considering both latent heat and flushing efficiency was built. With this model, the simulation of the crater on the wire was finished. Then based on the result gotten from the simulation and experiment, the heat partition ratio to the wire was found as 46.74% by inverse fitting. After that, a wire breakage experiment was done and through locating the position of 50 discharges before wire breakage it is found that 34% of discharges were located within a range of 2 mm, and the minimum area in the wire cross-section only remained 41.88% compared with the original wire. This kind of decrease in the cross-section area made the stress higher than the UTS of the wire and caused the wire breakage. The findings of this work allow for a more in-depth understanding of the effect of discharge accumulation on wire breakage.This work received funding support from the Spanish Min- istry of Economy and Competitiveness and the FEDER operation program for funding the project “Scientific models and machine-tool advanced sensing techniques for efficient machining of precision com- ponents of Low-Pressure Turbines” (DPI2017-82239-P)Springer Nature202520252023info:eu-repo/semantics/articleapplication/pdfhttp://hdl.handle.net/10810/72272reponame:Addi. Archivo Digital para la Docencia y la Investigacióninstname:Universidad del País VascoIngléshttps://link.springer.com/article/10.1007/s00170-022-10786-zinfo:eu-repo/semantics/openAccesshttp://creativecommons.org/licenses/by/3.0/es/This article is licensed under a Creative Commons Attribution 4.0 International LicenseAtribución 3.0 Españaoai:addi.ehu.eus:10810/722722026-06-18T09:23:17Z
dc.title.none.fl_str_mv Effect of discharge accumulation on wire breakage in WEDM process
title Effect of discharge accumulation on wire breakage in WEDM process
spellingShingle Effect of discharge accumulation on wire breakage in WEDM process
Wang, Jun
WEDM
wire breakage
heat partition
thermal model
discharge location
title_short Effect of discharge accumulation on wire breakage in WEDM process
title_full Effect of discharge accumulation on wire breakage in WEDM process
title_fullStr Effect of discharge accumulation on wire breakage in WEDM process
title_full_unstemmed Effect of discharge accumulation on wire breakage in WEDM process
title_sort Effect of discharge accumulation on wire breakage in WEDM process
dc.creator.none.fl_str_mv Wang, Jun
Sánchez Galíndez, José Antonio
Izquierdo Aramburu, Borja
Ayesta Rementeria, Izaro
author Wang, Jun
author_facet Wang, Jun
Sánchez Galíndez, José Antonio
Izquierdo Aramburu, Borja
Ayesta Rementeria, Izaro
author_role author
author2 Sánchez Galíndez, José Antonio
Izquierdo Aramburu, Borja
Ayesta Rementeria, Izaro
author2_role author
author
author
dc.subject.none.fl_str_mv WEDM
wire breakage
heat partition
thermal model
discharge location
topic WEDM
wire breakage
heat partition
thermal model
discharge location
description In recent years, WEDM has been adopted in precision machining as an important alternative machining method because of its greater flexibility and lower wear cost compared with traditional machining, whereas wire breakage during WEDM is an unignorable problem that influences the machining quality and efficiency. Therefore, it has been a research topic of considerable interest. This work focuses on exploring the reason for the wire breakage. Firstly, by observing the wire after discharges and using the finite element method, a complete thermal model considering both latent heat and flushing efficiency was built. With this model, the simulation of the crater on the wire was finished. Then based on the result gotten from the simulation and experiment, the heat partition ratio to the wire was found as 46.74% by inverse fitting. After that, a wire breakage experiment was done and through locating the position of 50 discharges before wire breakage it is found that 34% of discharges were located within a range of 2 mm, and the minimum area in the wire cross-section only remained 41.88% compared with the original wire. This kind of decrease in the cross-section area made the stress higher than the UTS of the wire and caused the wire breakage. The findings of this work allow for a more in-depth understanding of the effect of discharge accumulation on wire breakage.
publishDate 2023
dc.date.none.fl_str_mv 2023
2025
2025
dc.type.none.fl_str_mv info:eu-repo/semantics/article
format article
dc.identifier.none.fl_str_mv http://hdl.handle.net/10810/72272
url http://hdl.handle.net/10810/72272
dc.language.none.fl_str_mv Inglés
language_invalid_str_mv Inglés
dc.relation.none.fl_str_mv https://link.springer.com/article/10.1007/s00170-022-10786-z
dc.rights.none.fl_str_mv info:eu-repo/semantics/openAccess
http://creativecommons.org/licenses/by/3.0/es/
This article is licensed under a Creative Commons Attribution 4.0 International License
Atribución 3.0 España
eu_rights_str_mv openAccess
rights_invalid_str_mv http://creativecommons.org/licenses/by/3.0/es/
This article is licensed under a Creative Commons Attribution 4.0 International License
Atribución 3.0 España
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv Springer Nature
publisher.none.fl_str_mv Springer Nature
dc.source.none.fl_str_mv reponame:Addi. Archivo Digital para la Docencia y la Investigación
instname:Universidad del País Vasco
instname_str Universidad del País Vasco
reponame_str Addi. Archivo Digital para la Docencia y la Investigación
collection Addi. Archivo Digital para la Docencia y la Investigación
repository.name.fl_str_mv
repository.mail.fl_str_mv
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score 15,811543

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