Simulation of Wire EDM Combined with Measurements of Discharge Locations and Wire Displacement

Abstract

This paper describes a development of a wire electrical discharge machining simulation combined with the measurements of the wire displacement and discharge locations. The wire displacement was measured using an optical sensor to obtain the discharge reaction force and damping coefficient of the wire vibration which are variable during machining. The discharge locations were measured to obtain the points where the discharge reaction force is applied. Considering the discharge reaction force and electrostatic force acting on the wire electrode, the wire deflection and vibration were calculated to obtain the machined workpiece geometry to be compared with the experimental results. Most significant advantage of the simulation newly developed is that those parameters can be updated in real time during machining. With the help of the sensor fusion, the parameters were found to change with increasing the depth of cut and the cut geometries could be simulated with higher accuracy.