Scholarlink

<p>In wire electrical discharge machining, the recast layer removal on machined surfaces remains a critical challenge. While the rough trimming process can reduce its thickness, it will introduce significant straightness error. To resolve this dual challenge, an innovative hybrid processing strategy that synergistically combines wire electrical discharge machining with electrochemical machining (EDM-ECM) was proposed. This method demonstrated exceptional potential for effectively thinning or eliminating the recast layer while improving straightness. The study revealed that gas phase distribution generated by electrolysis played a pivotal role in determining discharge localization and material removal mechanisms. Through systematic single-pulse experiments under interpulse voltage regulation, the study identified distinct bubble distribution patterns corresponding to different voltage conditions. Then, a comprehensive bubble transport model has been developed. Finite element simulations further elucidated how gas-phase characteristics modulate electric field distributions, providing critical insights into the fundamental material removal mechanism during the wire EDM-ECM process. The experimental results indicate that the interpulse voltage can significantly enhance electrolytic efficiency. However, an excessive high voltage (&gt; 20&#xa0;V) can hinder the deionization capacity, thereby increasing abnormal discharge probability. Owing to the gas-phase distribution, the tip discharge effect can be weakened, and the discharge point transfer can be promoted. Compared to conventional rough trimming, the straightness error machined by the wire EDM-ECM was reduced by 38.8~64.5% across four pulse width conditions. The recast layer exhibited a unique inverse thickness distribution (edge-thickened/middle-thinned profile) with maximum thickness reduction reaching 31.4%.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Synergistic mechanism of bubble evolution and material removal during the rough trimming in wire EDM-ECM regulated by interpulse voltage

  • 期刊论文

  • 发表日期：

    2025年9月9日

查看全文
  • Ming Zhang,
  • Qiuying Zhao,
  • Yao Yao,
  • Zhen Yin,
  • Cong Deng

摘要

In wire electrical discharge machining, the recast layer removal on machined surfaces remains a critical challenge. While the rough trimming process can reduce its thickness, it will introduce significant straightness error. To resolve this dual challenge, an innovative hybrid processing strategy that synergistically combines wire electrical discharge machining with electrochemical machining (EDM-ECM) was proposed. This method demonstrated exceptional potential for effectively thinning or eliminating the recast layer while improving straightness. The study revealed that gas phase distribution generated by electrolysis played a pivotal role in determining discharge localization and material removal mechanisms. Through systematic single-pulse experiments under interpulse voltage regulation, the study identified distinct bubble distribution patterns corresponding to different voltage conditions. Then, a comprehensive bubble transport model has been developed. Finite element simulations further elucidated how gas-phase characteristics modulate electric field distributions, providing critical insights into the fundamental material removal mechanism during the wire EDM-ECM process. The experimental results indicate that the interpulse voltage can significantly enhance electrolytic efficiency. However, an excessive high voltage (> 20 V) can hinder the deionization capacity, thereby increasing abnormal discharge probability. Owing to the gas-phase distribution, the tip discharge effect can be weakened, and the discharge point transfer can be promoted. Compared to conventional rough trimming, the straightness error machined by the wire EDM-ECM was reduced by 38.8~64.5% across four pulse width conditions. The recast layer exhibited a unique inverse thickness distribution (edge-thickened/middle-thinned profile) with maximum thickness reduction reaching 31.4%.