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The material removal mechanism of WEDM is very similar to the conventional EDM process involving the erosion effect produced by the electrical discharges (sparks).In WEDM,material is eroded from the workpiece by a series of discrete sparks occurring between the workpiece and the wire separated by a streamof dielectric fluid,which is continuously fed to the machining zone [4].However,today’s WEDM process is commonly conducted on workpieces that are totally submerged in a tank filled with dielectric fluid.Such a submerged method of WEDM promotes temperature stabilisation and efficient flushing especially in cases where the workpiece has varying thickness.The WEDM process makes use of electrical energy generating a channel of plasma between the cathode and anode [5],and turns it into thermal energy [6] at a temperature in the range of 8000–12,000 vC [7] or as high as 20,000 vC [8] initialising a substantial amount of heating and melting of material on the surface of each pole.When the pulsating direct current power supply occurring between 20,000 and 30,000 Hz [9] is turned off,the plasma channel breaks down.This causes a sudden reduction in the temperature allowing the circulating dielectric fluid to implore the plasma channel and flush the molten particles from the pole surfaces in the formof microscopic debris.While the material removal mechanisms of EDM and WEDM are similar,their functional characteristics are not identical.WEDM uses a thin wire continuously feeding through the workpiece by a microprocessor,which enable parts of complex shapes to be machined with exceptional high accuracy.A varying degree of taper ranging from15 v for a 100 mm thick to 30v for a 400 mm thick workpiece can also be obtained on the cut surface.The microprocessor also constantly maintains the gap between the wire and the workpiece,which varies from0.025 to 0.05 mm [2].WEDM eliminates the need for elaborate pre-shaped electrodes,which are commonly required in EDM to perform the roughing and finishing operations.In the case of WEDM,the wire has to make several machining passes along the profile to be machined to attain the required dimensional accuracy and surface finish (SF) quality.Kunieda and Furudate [10] tested the feasibility of conducting dry WEDM to improve the accuracy of the finishing operations,which was conducted in a gas atmosphere without using dielectric fluid.The typical WEDM cutting rates (CRs) are 300 mm2/min for a 50 mm thick D2 tool steel and 750 mm2/min for a 150 mm thick aluminium [11],and SF quality is as fine as 0.04–0.25 lRa.In addition,WEDM uses deionised water instead of hydrocarbon oil as the dielectric fluid and contains it within the sparking zone.The deionised water is not suitable for conventional EDM as it causes rapid electrode wear,but its low viscosity and rapid cooling rate make it ideal for WEDM [12].
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The material removal mechanism of WEDM is very similar to the conventional EDM process involving the erosion effect produced by the electrical discharges (sparks).In WEDM,material is eroded from the workpiece by a series of discrete sparks occurring between the workpiece and the wire separated by a streamof dielectric fluid,which is continuously fed to the machining zone [4].However,today’s WEDM process is commonly conducted on workpieces that are totally submerged in a tank filled with dielectric fluid.Such a submerged method of WEDM promotes temperature stabilisation and efficient flushing especially in cases where the workpiece has varying thickness.The WEDM process makes use of electrical energy generating a channel of plasma between the cathode and anode [5],and turns it into thermal energy [6] at a temperature in the range of 8000–12,000 vC [7] or as high as 20,000 vC [8] initialising a substantial amount of heating and melting of material on the surface of each pole.When the pulsating direct current power supply occurring between 20,000 and 30,000 Hz [9] is turned off,the plasma channel breaks down.This causes a sudden reduction in the temperature allowing the circulating dielectric fluid to implore the plasma channel and flush the molten particles from the pole surfaces in the formof microscopic debris.While the material removal mechanisms of EDM and WEDM are similar,their functional characteristics are not identical.WEDM uses a thin wire continuously feeding through the workpiece by a microprocessor,which enable parts of complex shapes to be machined with exceptional high accuracy.A varying degree of taper ranging from15 v for a 100 mm thick to 30v for a 400 mm thick workpiece can also be obtained on the cut surface.The microprocessor also constantly maintains the gap between the wire and the workpiece,which varies from0.025 to 0.05 mm [2].WEDM eliminates the need for elaborate pre-shaped electrodes,which are commonly required in EDM to perform the roughing and finishing operations.In the case of WEDM,the wire has to make several machining passes along the profile to be machined to attain the required dimensional accuracy and surface finish (SF) quality.Kunieda and Furudate [10] tested the feasibility of conducting dry WEDM to improve the accuracy of the finishing operations,which was conducted in a gas atmosphere without using dielectric fluid.The typical WEDM cutting rates (CRs) are 300 mm2/min for a 50 mm thick D2 tool steel and 750 mm2/min for a 150 mm thick aluminium [11],and SF quality is as fine as 0.04–0.25 lRa.In addition,WEDM uses deionised water instead of hydrocarbon oil as the dielectric fluid and contains it within the sparking zone.The deionised water is not suitable for conventional EDM as it causes rapid electrode wear,but its low viscosity and rapid cooling rate make it ideal for WEDM [12].
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