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<p>With a certain proportion of no-load pulse, hydrogen is precipitated on the wire electrode during WEDM. Due to the higher proportion of no-load pulses in trimming, the material removal is the result of the combined action of electric spark discharge and electrolysis. To analyze the effect of bubble on straightness error during trimming, the high-speed camera combined with single pulse experimental device was used to analyze the influence of no-load pulse. CCD images show that the generation rate and size of hydrogen bubbles are affected by the current density. Side-by-side hydrogen bubbles can enhance the electric field intensity, and the smaller the diameter, the greater the distortion of electric field intensity. The colloid produced by electrolysis can wrap bubbles and discharge products. The existence of bubbles increases the probability of series discharge and reduces the uniformity of discharge along the thickness direction of the workpiece. As the pulse width increases from 5 to 7&#xa0;μs, the bubble diameter increases from 10 to 20&#xa0;μm, but the straightness error increases by 34%. When the pulse width is small, the number of power tubes will not increase the straightness error significantly. The conductivity has an important effect on the straightness error. Compared with 1.7-μm straightness error with tap water during trimming, the 1:10 concentration of JR1A is 3.35 times higher.</p>

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Influence of bubble distribution produced by no-load pulse on straightness error in WEDM trimming

  • 期刊论文

  • 发表日期：

    2025年8月16日

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  • Ming Zhang,
  • Cong Deng,
  • Yao Yao,
  • Zhen Yin

摘要

With a certain proportion of no-load pulse, hydrogen is precipitated on the wire electrode during WEDM. Due to the higher proportion of no-load pulses in trimming, the material removal is the result of the combined action of electric spark discharge and electrolysis. To analyze the effect of bubble on straightness error during trimming, the high-speed camera combined with single pulse experimental device was used to analyze the influence of no-load pulse. CCD images show that the generation rate and size of hydrogen bubbles are affected by the current density. Side-by-side hydrogen bubbles can enhance the electric field intensity, and the smaller the diameter, the greater the distortion of electric field intensity. The colloid produced by electrolysis can wrap bubbles and discharge products. The existence of bubbles increases the probability of series discharge and reduces the uniformity of discharge along the thickness direction of the workpiece. As the pulse width increases from 5 to 7 μs, the bubble diameter increases from 10 to 20 μm, but the straightness error increases by 34%. When the pulse width is small, the number of power tubes will not increase the straightness error significantly. The conductivity has an important effect on the straightness error. Compared with 1.7-μm straightness error with tap water during trimming, the 1:10 concentration of JR1A is 3.35 times higher.