Prediction of wire-EDMed surface shape by in-process measurement of wire electrode behavior

Abstract

In wire electrical discharge machining (WEDM), it is necessary to control the wire orientation accurately. However, the control is difficult because of the complex behavior of the wire during cutting caused by bubble expansion, electrostatic force and electromagnetic force. Therefore, it is important to measure the deflection and vibration of the wire in-process and to predict the machined surface shape. This paper describes the in-process measurement of the wire behavior using a sensor newly developed. The surface shape predicted from the wire behavior coincided well with the surface shape measured after machining.