Abstract
This study analyzes the limitations of servo control systems for high-speed wire cut electrical discharge machining (HSWEDM). The discharge gap cannot be adjusted in real time during large energy cutting, as this will prevent interelectrode dielectric liquid from entering the discharge gap steadily, leading to violent vaporization and resulting in surface burning of the workpiece. This study proposes a new servo control system for HSWEDM based on discharge probability detection. The system collects the interelectrode discharge signal by dividing and comparing voltage circuits and then calculating discharge probability in a field-programmable gate array (FPGA), after which the machine tool adjusts feed rate by comparing the actual and initial target discharge probability. Thus, proper and stable discharge gap are ensured, enabling the interelectrode dielectric liquid to remain constant, increasing efficiency and stability, and decreasing surface burning effectively. Experiments prove that a servo control method based on discharge probability detection can increase stable cutting speed to 180 mm2/min and workpiece surfaces show no apparent burning stripes. In addition, the highest cutting speed can be increased to 208 mm2/min.
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He, X., Liu, Z., Pan, H. et al. Increasing process efficiency of HSWEDM based on discharge probability detection. Int J Adv Manuf Technol 93, 3647–3654 (2017). https://doi.org/10.1007/s00170-017-0742-y
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DOI: https://doi.org/10.1007/s00170-017-0742-y