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<p>This paper presents a high-efficiency micro wire electrical discharge machining (micro-WEDM) method employing reciprocating multi-wire electrodes with a diameter of 50&#xa0;μm. To achieve stable multi-channel discharge, two-roller, three-roller, and four-roller micro-wire winding configurations are investigated. A multi-degree-of-freedom vibration model is established to analyze the natural frequencies of the micro-wire traveling system, and the tension variation characteristics in the machining region are further examined under different winding modes. Based on these analyses, a multi-wire micro-WEDM method and a corresponding three-roller winding mechanism are developed and validated through machining experiments. The effects of the number of wire electrodes on machining efficiency and accuracy are first evaluated, indicating that micro double-wire EDM provides an effective balance between efficiency and precision. Subsequently, the influences of open-circuit voltage, discharge capacitance, and feed rate on machining performance are systematically investigated to determine suitable processing parameters. Finally, the proposed method is successfully applied to the fabrication of a micro relay, achieving high machining efficiency and dimensional accuracy, which demonstrates its feasibility and practical potential.</p>

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Study on micro reciprocating multi-wire electrical discharge machining

  • 期刊论文

  • 发表日期：

    2026年6月29日

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  • Xiang Chen,
  • Yukui Wang,
  • Yuanming Zhao,
  • Jiayi Deng,
  • Cheng Guo,
  • Kangcheung Chan,
  • Zhenlong Wang

摘要

This paper presents a high-efficiency micro wire electrical discharge machining (micro-WEDM) method employing reciprocating multi-wire electrodes with a diameter of 50 μm. To achieve stable multi-channel discharge, two-roller, three-roller, and four-roller micro-wire winding configurations are investigated. A multi-degree-of-freedom vibration model is established to analyze the natural frequencies of the micro-wire traveling system, and the tension variation characteristics in the machining region are further examined under different winding modes. Based on these analyses, a multi-wire micro-WEDM method and a corresponding three-roller winding mechanism are developed and validated through machining experiments. The effects of the number of wire electrodes on machining efficiency and accuracy are first evaluated, indicating that micro double-wire EDM provides an effective balance between efficiency and precision. Subsequently, the influences of open-circuit voltage, discharge capacitance, and feed rate on machining performance are systematically investigated to determine suitable processing parameters. Finally, the proposed method is successfully applied to the fabrication of a micro relay, achieving high machining efficiency and dimensional accuracy, which demonstrates its feasibility and practical potential.