Abstract
Wire breakage (tool failure) is encountered in many industrial applications (e.g. cutting of complex contours) of Wire Electrical Discharge Machining (WEDM). This paper describes an on-line WEDM monitor, and proposes a control strategy to prevent wire rupture. The monitoring system detects the sparking frequency which is correlated with the wire breakage phenomena. A large number of sparking frequency data during the process has been analyzed. Features of the sparking frequency leading to wire breakage have been identified. The new control strategy proposes to control the sparking frequency at a constant level for avoiding wire rupture and improving productivity.
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