Ultra-long Wire Reciprocated-WEDM with Dual Tensile Reels Winded

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The MS-WEDM belongs to HS-WEDM machine tool category. It makes multi-cutting processing come true on a HS-WEDM machine tool. The cutting quality of this method is bad, but compared with LS-WEDM, it has lower machining cost. The LS-WEDM is unidirectional wire feeding electrical discharge machining with low speed, and after discharging, the wire electrode is discarded. It has a good surface quality, but the cost is higher. In this paper, a design scheme of ultra-long wire (the length of the wire is 10km) reciprocated-WEDM with dual tensile reels winded and the corresponding processing method are given. These can obviously improve the machining precision of the MS-WEDM and the finish of the work piece. Through developing reciprocatable, variable-speed and ultra-long wire feeding two tensile reels system, the HS-WEDM and the LS-WEDM are banded together well. Based on the study of the kinetic mechanism of the constant tension feeding wire electrode, a combined machining method is found. With this method, the work piece is cut by high-speed reciprocating wire first, and then is finished by the wire with unidirectional movement at low speed. This method can eliminate the reversal stripe caused by reciprocated-WEDM. The same finish technique as LS-WEDM is achieved. The positive unidirectional wire feeding WEDM of the ultra-long wire feeding dual tensile reels system is also studied in this paper. The cutting quality is much better than reciprocated-WEDM. So, ultra-long wire reciprocated-WEDM with dual tensile reels winded creates good conditions for the machining quality of the MS-WEDM to approximate that of the LS-WEDM. Compared with the LS-WEDM, the wire electrode is recyclable. So the consumption of the wire electrode is reduced apparently.