Abstract
High Speed Wire EDM (HSWEDM) is a technology that differs from conventional wire EDM in many aspects like polarity, pulse duration, discharge formation, working medium, wire material and speed. The comparably high relative velocity between the wire and the workpiece is one of the key characteristics of HSWEDM. Its main effect lies in improved flushing that allows high cutting rates to be achieved by this technology. In this study, discharge locations and cutting speeds were determined. Additionally, traces of single discharges on the workpiece surface were measured using a profilometer. Results show that flushing effects tend to vary significantly depending on the wire direction of the (vertically) reciprocating wire. Also, by mapping the number of discharges, considerable differences of the machining efficiency were found within complex workpiece geometries. However, the high wire velocity also affects the formation of the discharges as (other than in conventional wire EDM) relative motion during a discharge cannot be neglected. Additionally, indications of electrochemical material removal could be observed.
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