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<p>The problem of high energy consumption due to low material removal rate is prominent in the wire electrical discharge machining. This paper studies the effect of trimming process on energy consumption, analyzes the possibility of reducing energy consumption through trimming process, and proposes an energy optimization method based on trimming process to reduce energy consumption. The following five trimming parameters were considered: pulse on time, pulse off time, number of amplifier tubes, machining speed limit and machining allowance. The solution set of machining parameters is obtained by multi-objective optimization with surface roughness and energy consumption per unit area of machining. Experimentally verified trimming energy consumption prediction model accuracy of about 94.3%. The experimental results demonstrate that when machining Cr12 workpieces with a thickness of 24&#xa0;mm and requiring a surface roughness value of less than 3&#xa0;μm, the machine tool utilized in this experiment can achieve reduced energy consumption in comparison to single cutting process by employing optimized trim cut parameter settings for trimming process. When the workpiece with roughness requirement of 2.5&#xa0;μm is processed, the lowest unit area energy consumption of cutting process is 2436.536&#xa0;J/mm<sup>2</sup>, while that of trimming process is 1665.480&#xa0;J/mm<sup>2</sup>, which is reduced by 31.6%. The study demonstrates the energy-saving potential of trimming process in precision machining. The optimization method provides a basis for selecting the most energy-efficient strategy (trimming or single cutting process) and configuring parameters based on specific surface quality requirements.</p>

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Optimizing trimming process parameters to reduce energy consumption in wire electrical discharge machining

  • 期刊论文

  • 发表日期：

    2026年2月20日

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  • Jun Zheng,
  • Zhushun Xia,
  • Wei Wang,
  • Bojie Xv,
  • Rundong Jia,
  • Jun Zhu,
  • Xiran Qiu,
  • Changjiang Yang,
  • Haojun Xv,
  • Cong Deng,
  • Wei Ling,
  • Zhiyi Zhang

摘要

The problem of high energy consumption due to low material removal rate is prominent in the wire electrical discharge machining. This paper studies the effect of trimming process on energy consumption, analyzes the possibility of reducing energy consumption through trimming process, and proposes an energy optimization method based on trimming process to reduce energy consumption. The following five trimming parameters were considered: pulse on time, pulse off time, number of amplifier tubes, machining speed limit and machining allowance. The solution set of machining parameters is obtained by multi-objective optimization with surface roughness and energy consumption per unit area of machining. Experimentally verified trimming energy consumption prediction model accuracy of about 94.3%. The experimental results demonstrate that when machining Cr12 workpieces with a thickness of 24 mm and requiring a surface roughness value of less than 3 μm, the machine tool utilized in this experiment can achieve reduced energy consumption in comparison to single cutting process by employing optimized trim cut parameter settings for trimming process. When the workpiece with roughness requirement of 2.5 μm is processed, the lowest unit area energy consumption of cutting process is 2436.536 J/mm2, while that of trimming process is 1665.480 J/mm2, which is reduced by 31.6%. The study demonstrates the energy-saving potential of trimming process in precision machining. The optimization method provides a basis for selecting the most energy-efficient strategy (trimming or single cutting process) and configuring parameters based on specific surface quality requirements.