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A macroscopic mechanical model of wire electrode deflection considering temperature increment in MS-WEDM process Zhi Chen, Zhen Zhang, Guojun Zhang, Yu Huang, Wuyi Ming, He Li

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S0890-6955(14)00011-X http://dx.doi.org/10.1016/j.ijmachtools.2014.01.004 MTM2924

International Journal of Machine Tools & Manufacture

Received date: 26 September 2013 Revised date: 19 January 2014 Accepted date: 23 January 2014 Cite this article as: Zhi Chen, Zhen Zhang, Guojun Zhang, Yu Huang, Wuyi Ming, He Li, A macroscopic mechanical model of wire electrode deflection considering temperature increment in MS-WEDM process, International Journal of Machine Tools & Manufacture, http://dx.doi.org/10.1016/j.ijmachtools.2014.01.004 This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting galley proof before it is published in its final citable form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.

A macroscopic mechanical model of wire electrode deection considering temperature increment in MS-WEDM process
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Abstract In medium-speed wire electrical discharge machining (MS-WEDM), wire in the area near the guide wheel and between the two guide wheels obviously form the wire bending deformation due to wire tension, electrostatic force, electrodynamics force, hydrodynamic force and temperature increment, etc. Besides, the wire deection would have a direct inuence on the machining accuracy, productivity and stability. In this paper, rst of all, main causes of wire electrode deformation are proposed to better understand its fundamental mechanism. Secondly, two macroscopic mechanical models of wire deection are developed in the area near the guide wheel and between the two guide wheels considering temperature increment and wire vibration in machining 20mm-thickness workpiece process, respectively. Moreover, the numerical solution of deection in the area near the guide wheel and the theoretical solution of deection between the two guide wheels have been worked out. Then, the analysis of the variation trend of wire deection and the inuences of wire deection on the machining process has been conducted. Eventually, from the conrmation experiment and comparison with other researchers models, it has been proved that the macroscopic mechanical models of wire deection in MS-WEDM process are reasonable and reliable. In addition, according to macroscopic mechanical models, some the practical approaches of reducing wire deection have been proposed to improve machining accuracy, and these high-precision models can be applied into NC system to set a compensation for wire deection in the future. Keywords: Medium-speed wire electrical discharge machining; Wire deection; Macroscopic mechanical model; Discharge resultant force; Temperature increment

1. Introduction Wire electrical discharge machining (WEDM) is a highprecision and independent of material hardness machining operation, mainly used in the mold, instrument and other highend manufacturing industries. The WEDM process is a violent thermal process where a certain volume of metal is eroded by thousands of electrical discharges in a fraction of one second. Up to now, the WEDM can be classied as high-speed WEDM (HS-WEDM) and low-speed WEDM (LS-WEDM) based on the wire speed. HS-WEDM is a new product of independent innovation in China, which has taken up more than 85% of Chinese domestic market due to the advantages of lower cost and high eciency. However, LS-WEDM has more advantages in aspects like working accuracy, control strategy and surface quality. Therefore, a large number of studies have been made to narrow the gap between HS-WEDM and LS-WEDM, thus developing a new concept called Medium-speed WEDM (MSWEDM). Improved control strategy, high frequency power

Figure 1: Schematic diagram of MS-WEDM

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supply and NC system on the basis of HS-WEDM, MS-WEDM can be obtained, which realizes multiplicity cutting in higher capacity to achieve high machining performance. In addition, there is a tendency that MS-WEDM will take the place of HS-WEDM in China. Fig.1 shows the schematic diagram of the MS-WEDM process, the wire electrode is circularly moving on the two guide wheels and wire-winding cylinder. In the MS-WEDM machining process, the wire electrode certainly suers wire deection in the area near the guide wheel
January 30, 2014

Nomenclature 0 m m n 0 e m h B x y Az damping coecient (Eq.40) (N s m 1 ) dielectric uid viscosity coecient (Eq.6) (N s m 2 ) induction-permeability (Eq.2) (H/m) electric potential (Eq.2) (V) natural circular frequency (Eq.42) (Hz) wire density (Eq.19) (Kg m 3 ) uid density (Eq.3) (Kgm 3) electric resistivity (Eq.10) (nm) electric conductivity (Eq.2) (S/m) viscosity force (Eq.7) (N) rotation angle (Fig.11) (radian) central angle AOB (Fig.10) (radian) rotation angle only by the eect of F x (Eq.14) (radian) rotation angle only by the eect of F y (Eq.16) (radian) electromagnetic vector potential Z -component (Eq.2) (Gs) specic heat (Eq.9) (J/(kgK)) Fy component force in the y direction of the wire tension (Fig.12) (N) single discharge impact force (Eq.39) (N/m) electrostatic force (Eq.1) (N)

Fd Fe

F p (t) discharge impact force (Eq.39) (N/m) Fx component force in the x direction of the resultant force (Fig.10) (N) component force in the y direction of the resultant force (Fig.10) (N) workpiece thickness (Eq.10) (m) heat transfer coecient (Eq.10) (W/(m 2 K)) second moment of area (Eq.12) (m 4 ) discharge current (Eq.1) (A) forced current density (Eq.2) (A/m 2 ) curvature near the section B (Fig.10) (m) coecient of distributed resultant force per unit current (Eq.47) (N/(mA)) thermal conductivity (Eq.9) (W/(mK)) two guide wheels span (Fig.12) (m)

Fy

h hT I I (t) J0 k kq

kT L

cT

distance between the wire guide wheel and the workpiece (Fig.11) (m)

d0 d1 DF E

discharge gap (Fig.3) (m) discharge breakdown distance (Eq.44) (m) kerf width (Fig.14) (m) Youngs modulus at room temperature (Eq.12) (1011 Pa)

M E bending moment at the point E (Fig.10) (Nm) ns p q discharge number on one spot (Eq.39) uid pressure (Eq.3) (Pa) distributed resultant force per unit length (Fig.11) (N/m) joule heat source (Eq.10) (w/mm 2)

E(T ) Youngs modulus function about temperature (Tab.2) (1011 Pa) E(t) discharge energy (Eq.46) (J)

qJ R

guide wheel radius (Fig.10) (m)

Nomenclature r S T wire radius (Fig.10) (m) wire electrode cross-sectional area (Eq.1) (m 2 ) wire tension (Fig.10) (N) ve Xi y1 y2 y0 y1 y2 yE yx yy electron speed (Eq.1) (m/s) volume component( x, y, z) (Eq.3)(m 3) wire deection of tting model in the non-discharging area (Eq.51) (m) wire deection of tting model in the discharging area (Eq.50) (m) total deection in coordinate system O (Fig.10) (m) wire deection in the non-discharging area (Fig.11) (m) wire deection in the discharging area (Fig.12) (m) total deection in coordinate system O 1 (Fig.10) (m) deection only by the eect of F x (Eq.13) (m) deection only by the eect of F y (Eq.15) (m)

resultant force of wire tension and wire inertia force (Fig.10) (N) discharge channel temperature (Eq.8) ( C) the pulse period (Fig.2) (s) pulse-on time (Fig.2) (s)

TC tp ton

to f f pulse-o time (Fig.2) (s) ui velocity component( x, y, z) (Eq.3) (m/s)

U(t) discharge voltage (Eq.1) (V) v wire speed (Fig.12) (m/s)

and between the two guide wheels because of the wire tension, the radial jumpiness and axial running of the wire-winding cylinder and the guide wheels, the plasma of the erosion mechanism, hydraulic forces due to dielectric uid ushing, electrostatic force, electrodynamics force and temperature increment [1]. These wire deection can be of the order of a few hundred microns [2] and they will alter the actual fulcrum of the wire electrode at the guide wheels, especially in the corner cutting, which will result in great diculty in developing the processing performance (eciency, accuracy, surface integrity, etc.). Thus, it is necessary to better understand the fundamental mechanism of the wire deformation and develop a high-precision model of wire deection, and propose some eective methods controlling the wire electrode in order to improve the machining precision in MS-WEDM. There are some previous researches about the wire trajectory have been carried out. Dauw, D. F. and Beltrami, I. [2, 3] designed a system based on the on-line monitoring and controling of the wire trajectory by method of an optical sensor, and these techniques allowed to machine complex shapes at a high cutting speed and obtain high precision simultaneously. Sarkar, S. and Kanlayasiri, K. [4, 5, 6] set the wire oset as an input parameter in trim cutting, therein, setting a suitable wire oset had a direct eect on machining accuracy. Hsue, W. J. [7] pro3

posed a method that the actual trajectory of wire center can be tted as an exponential function in practical corner cutting, and a model of metal removal rate( MRR) in geometrical machining was built considering the wire deection. While Sanchez, J. A. [8] used a quadratic regression tting method to predict angular error in wire-EDM taper-cutting, and an experimental analysis of the main eects of control parameters on angular error was carried out by the method of Design of Experiments (DoE) techniques. Luo, Y. F. [9] developed a new practical model, an arc tting, to evaluate the wire bow error, and an equation of wire bow error had been derived to implement some approaches reducing this error. Puri, A. B. [2, 10] proposed a new approach, a parabolic tting, to illustrate the wire trajectory, and an experimental investigation had been carried out to nd out the relationship between the control factors and the wire lag based on the Taguchi method. Han, Fuzhu and Sanchez, J. A. [11, 12] executed a novel simulation method to calculate the wire electrode path in corner-cutting and taper-cutting, respectively, and a geometrical model between the wire actual path and NC path was set up to investigate the relationship between the wire actual trajectory and NC trajectory. Mingqi, L. [13] proposed some corresponding measures to stabilize the form and position of the wire electrode in the HS-WEDM machining process by experimental design and analysis. In

above studies, some theoretical models and experimental methods had been developed to improve the machining accuracy, but few theoretical models had been veried by experiment. Moreover, temperature increment, electrostatic force and wire vibration had been seldomly considered in analyzing the wire electrode deformation. In this paper, rstly, some causes of wire electrode deformation, including discharge spark force, electromagnetic force, electrostatic force, hydrodynamic viscous force, removing material explosive force and temperature increment, etc., are analyzed in detail to better understand the fundamental mechanism of wire deformation. Secondly, two macroscopic mechanical models of wire deection are built in the area near the guide wheel and between the two guide wheels considering temperature increment and wire vibration in machining 20mm-thickness workpiece process, respectively. The former model is developed by the method of numeric calculation, while the latter one is established by the method of fourth-order function tting. Then, the numerical solution of wire deection in the area near the guide wheel and the theoretical solution of deection between the two guide wheels have been worked out, respectively. Moreover, the feasibility of models is conrmed by the conrmation experiment and comparison with other researchers models. Finally, some practical measures of reducing wire deection are proposed through the analyzing the variation of wire deection and the inuence trends of machining factors on wire deection on the machining process. In the future work, these high-precision models can be applied into NC system to set a suitable compensation for wire deection

ergy is provided by a high frequency pulse electrical generator. The discharge reaction force includes discharge spark force, removing material explosive force, dielectric uid bubble diusive and disruptive force, and so on. In addition, the direction of discharge reaction force is opposite to the cutting direction, and it is a damping force which pulls the wire actual path behind the wire CNC path. Moreover, it is very dicultly to measure these forces accurately because there are violent explosion process and some stochastic processes in machining process, such as randomness of discharge point, randomness of discharge condition of pulse generator and violent molecular collision, while its value is directly related to the discharge energy per pulse. Therefore, considering this complicated fact, some researchers found that the discharge reaction force was the main cause of wire deformation, and they treated it as a distributed force acting per unit length of the wire according to statistic analysis[2, 3, 9, 10]. Besides, the value of discharge reaction force had been calculated by experimental data and theoretical models in their studies, and the computed results showed that the discharge reaction force ranged from 1.55N/m when the discharge energy ranged from 510mJ per pulse.

2.2. Electrostatic force and electromagnetic force Electrostatic force is an interaction force acting on two static charged objects, and its value obeys the coulomb law. In the wire electrical discharge machining process, electrostatic force when open voltage is acting on the wire and workpiece during ignition delay time, and it will become weak when the discharge spark occurs. Besides, it is an attractive force which attracts the wire electrode to the workpiece in cutting direction, and it osets each other on both side of cutting direction. In this study, the schematic diagram of pulse voltage and analysis diagram of electrostatic eld are shown in Fig.2 and Fig.3, respectively. Electrostatic eld can be regard as a uniform electrostatic eld during ignition delay time because the wire electrode diameter (2r) is more than 10 times as big as the discharge gap (d 0 ) between the workpiece and wire electrode (2r=180m, d 0 =4m). So the electrostatic force can be calculated by Eq.1. Fe = I(t) U(t) S Ve d0 (1)

2. The analysis of some causes of wire electrode deformation WEDM is a very complicated process which involves several elds, such as mechanics of materials, electromagnetism, hydrodynamics, heat transfer theory, and so on. In this section, some causes of wire electrode deformation are analyzed to better comprehend the the fundamental mechanism of wire deformation which are discharge reaction force, electrostatic force and electromagnetic force, hydrodynamic force and temperature increment, respectively.

2.1. Discharge reaction force WEDM is a violently material removing and non-contact discharging process in dielectric uid, and the machining en4

According to Eq.1, it can be found that the electrostatic force is directly proportional to pulse current (I (t) ) when other discharge parameters remain constant. As for electromagnetic force, Tomura S. claried the mecha-

Figure 4: Trapezoidal pulse current in wire used for analysis

Figure 2: Schematic diagram of pulse voltage

nism of electromagnetic force acting on the wire electrode, and developed a two-dimensional nite element method (FEM) to analyze the electromagnetic eld in cutting process of copper and steel, respectively [14]. Hada K. developed a simulation method to evaluate the distribution of the current density and magnetic ux density around the wire electrode to nd out the optimum machining conditions by nite element method (FEM) in WEDM [15]. The two-dimensional electromagnetic eld can be solved by the Poissons equation (as shown in Eq.2) in consideration of the electromagnetic induction. 1 Az Az m 1 Az ( )+ ( ) = J0 + m + x m x y m y t z (2)

Figure 3: The analysis diagram of electrostatic eld

In analysis of the eect of electromagnetic force on workpiece, the workpiece material should be divided into paramagnetic and ferromagnetic part, and the electric current density and magnetic ux density are of symmetrical distribution around the wire electrode when the workpiece is paramagnetic material. However, the electric current density and magnetic ux density are not axisymmetrical around the wire due to the signicant eect of the workpiece of ferromagnetic material. In Tomura S. study, the values of electromagnetic force had been quanticationally calculated by nite element method (FEM) in machining copper and steel process, where the discharge pulse current(I (t)) ( maximum current: 16A) was shown in Fig.4, and the values of electromagnetic force in machining copper and steel process was shown in Fig.5. From Fig.5, it can be found that the directions of the electromagnetic force of copper and steel material are repulsive and attractive, respectively. This fact may be attributed to the dierent magnetic conductivities of two kinds material. In addition, it can be also found that the value of electromagnetic force rose to the maximum (0.08N/m, 0.12N/m) in a short 5

Figure 5: The calculated value of electromagnetic force in machining copper and steel[14]

time (2s) due to the eddy current, and remained stable over a long period of time, then dropped to zero in a short time (2s).

2.3. Hydrodynamic viscosity force The dielectric uid is three-dimensional incompressible viscous liquid, and its motion state obeys the Navier-Stokes equations, as shown in Eq.3. 1 p 2 ui dui = Xi +v 2 dt 0 xi x j (3)
Figure 6: the schematic diagram of pressure-dierence ow (a) and shear ow (b)

Because wire electrode diameter (2r) is more than 10 times as large as the discharge gap (d 0 ) between the workpiece and wire electrode (r=180m, d 0 =4m), the liquid motion can be regard as the viscous uid movement between two large plates, and the liquid motion can be treated as the combination of pressure-dierence ow and shear ow, as shown in Fig.6 (a) and (b). Besides, the uid owing is a volume conservation system due to incompressibility. According to volume conservation equation (Eq.4) and momentum conservation equation (Eq.5), the speed of uid particle (uy ) and the viscosity force acting on the wire electrode can be work out, as shown in Eq.6 and Eq.7, respectively, and the viscosity coecient can be obtained by Eq.8 in dierent temperatures (T C ). u v w + + =0 x y z (4)

0 =

0.01779 2 1 + 0.03368T C + 0.000221T C

(8)

Through above analysis, it can be seen that the directions of wire electrode movement and viscosity force are in the same line, besides, the value of viscosity force acting on the wire electrode is about 0.10.5N when the computational condition is as follows: uid temperature (201000 C), wire velocity (10m/s), uid pressure (1Mpa), discharge gap (4m). Hence, viscosity force of dielectric uid is an insignicant cause of wire deection compared to the wire tension (1030N).

2.4. Eect of temperature increment WEDM is also a violent thermal process, and material is removed by melting and evaporating at a high temperature (maximum temperature may amount to 1000K) in a very short time. In this subsection, an one-dimensional thermal model is developed with the length-axis of the wire in the discharge channel, and the conguration of heat sources and model setup is shown in Fig.7. Besides, molybdenum wire is used as electrode in WEDM. Assuming that the joule heat source is uniformly distributed 6

u u u u 1 p 2 u 2 u 2 u +u +v +w = + v( 2 + 2 + 2 ) (5) t x y z 0 x x y z uy = v 1 p 2 (d y2 ) (y + d0 ) 2d0 2u0 x 0 v d0 p ) + 2d0 0 x (6) (7)

h = 0 (

Table 1: Values of material property and other parameters used for calculating the wire temperature distribution

Symbol Material Property kT cT

Figure 7: The conguration of heat sources and model setup

Value 138 24.06 23507 10.28 53.4 10

Unit W/(mK) kgK W/(m 2 K) kg m 3 n m m/s

Thermal conductivity Specic heat Heat transfer coecient Wire density Electric resistivity Wire velocity Joule heat source Wire radius Fluid pressure Workpiece thickness Pulse current Pulse voltage

hT

along the wire length, and the environment temperature maintains stable, the one-dimensional heat ow equation can be simplied as Eq.10, and the values of material property and other parameters used for calculating the wire temperature are listed in Tab.1. m= CT v kT (9) (10)

e v qJ r p h I(t) V(t)

1.68.0 w/mm 2 90 1 20 1 5 100 m Mpa mm A V

q d2 T ( x,t) dT ( x,t) hT L m T ( x, t) = J 2 dx kT S kT dx

Here, the joule heat source discharge energy is just decided by the pulse current when the other discharge parameters remain constant (pulse voltage 100V, pulse-on time 50s, pulse-o time 250s). Eq.10 can be solved by the method of variables separation and boundary condition, as follows: Upper part:dT ( x=)/dx=0,T ( x=) =20 Lower part:dT ( x=+) /dx=0,T ( x=+)=20 The solution of the temperature distribution along the wire length axis is shown in Fig.8 by above analysis. Fig.8 presents that the maximum temperature has an increasing trend with the rise of joule heat source energy, and temperature symmetrically distributes on the both side of workpiece midpoint. In addition, the values of the maximum temperature generally conform to the experimental measurement data on each pulse currents. Temperature increment has a few eect on wire movement, and this eect involves intensifying molecular motion, changing of the dielectric uid viscosity coecient and material property (tensile strength, Youngs modulus, fatigue strength and breaking tenacity, etc.). This subsection aims to analyze the causes of wire deection, and hence the variation of the Youngs modulus of wire electrode, viscosity coecient and pressure of the dielectric uid should be discussed because of temperature increment. 7

Figure 8: Distribution of temperature along the length axis of wire in the discharge channel

due to temperature increment has been acquired as Tab.2.

3. Models of wire deection in MS-WEDM process In this section, two macroscopic mechanical models, which are wire deection in the area near guide wheel, wire deection and wire vibration between the two guide wheels respectively, are developed to qualitatively estimate the wire electrode deformation considering the temperature increment and wire vibration behavior.

3.1. Model of wire deection in the area near guide wheel

Figure 9: The relationship polt of Youngs modulus and temperature[16]

Table 2: Values of material property and other parameters used for calculating the wire temperature

Values Parameters Pulse current I (A) Joule heat source q J (w/mm2) Average temperature T C ( C) Youngs modulus E (T ) (1011Pa) 1 2 3 4 5

1.6 3.2 4.8 6.4 8 318 402 471 532 564 3.02 2.93 2.85 2.77 2.73

According to Rare Metal Handbook Edition Committee[16], the Youngs modulus of molybdenum wire is illustrated in Fig.9 when the temperature varies from 0 C to 1600C. Combining Tab.1, Fig.8 and Fig.9, it can be summarized as Tab.2, the values of Youngs modulus are obtained in dierent discharge parameters. Based on above analysis in this section, it can be concluded as follows: 1. Discharge reaction force is the major force acting on the wire electrode, and it can be treated as a distributed force acting per unit length of the wire. 2. Electrostatic force is an interaction and attractive force acting on the wire and workpiece just during ignition delay time, and its value is directly proportional to pulse current when other discharge parameters remain constant. 3. Electromagnetic force and dielectric uid viscosity force are insignicant causes of wire deection compared to the discharge reaction force and wire tension, respectively. 4. The variation trend of the Youngs modulus of wire electrode 8

In the actual MS-WEDM process, there is a particular wire deection in the area near guide wheel due to the wire circularly moving on the two guide wheels and wire-winding cylinder, and this deection can range from 20m to 100m. As the Fig.10 draws, wire electrode generates the elastic bending deformation (y 0 ) which is away from common tangent of the guide wheels rather than placing exibly at the tangent point (A) of the guide wheel. The actual direction of wire tension T turns 90 , but wrap angle of wire electrode on the guide wheel is less than 90 . Thus the actual tangent point moves from A to B. From the point B to the point E (E section is a free end without bending moment and shear force, and only under the resultant force T of wire tension T and wire inertia force), this part of wire electrode suers the deection. By the analysis of the part of BE, the central angle AOB ( B ) can be approximately regarded as the rotation angle of bending deformation. Due to the ( B ) less than 102 rad, the BE part can be considered as the cantilever beam with one end xed and another end free, and the whole bending deformation can be regarded as the small deformation. In the Fig.10, two rectangular coordinate systems have been established at the center point O of the circle and the point O 1 respectively. The resultant force T of wire tension T and wire inertia force can be divided into F x and F y at the E free end. According to the Mechanics of Materials equations. Bending moment: ME = F y x E F x y E (11)

All the curvature k near the section B is the equal, and then k = R + r. Another bending moment: ME = EI k (12)

F x = T cos B + S v2 (1 cos B ) Fy = T sin B S v2 sin B From Eq.11 to Eq.20, it can be concluded as follows.

(19) (20)

ME = (T S v2 ) xE sin B (T cos B + S v2 (1 cos B ))yE (21) 1 1 2 2 (T S v2 ) x3 E sin B (T cos B +S v (1cos B ))y E xE 3 2 (22)

EIyE =

EI B =

1 2 (T S v2) x2 E sin B (T cos B + S v (1 cos B ))y E xE 2 (23)

Figure 10: Bending deformation of wire electrode in the area near guide wheel

The total deection y 0 in the rectangular coordinate systems of the point O can be deduced through geometric relationship in the Fig.10. y0 = ((r + R) R cos B + ( xE R sin B ) tan B yE ) cos B r (24)

The deection only by the eect of F x can be considered as the bending deformation due to free end subjected to bending moment load. Thus Eq.13 and Eq.14 can be deduced. 1 EIy x = F x yE x2 E 2 EI x = F x yE xE (13) (14)

It is dicult to calculate the analytical solutions of y E , xE , B , because Eq.21-23 are the trigonometric equations. In the actual machining process, E , I , R, r, T , S , v, are the given values, while yE , xE , B are the unknown values. Thus, by the use of the symbolic equation in MATLAB, the numerical solutions can be worked out and then be applied in the objective function (Eq.24) to gain the wire deection (y 0 ) in the area near the guide wheel. 3.2. Model of wire deection between the two guide wheels In this subsection, a model of wire lag without the consideration of wire vibration and a model of wire vibration behavior between the two guide wheels are built, respectively. Moreover, the maximum deection can be obtained by maximum wire lag and vibration amplitude according to vector superposing method.

The deection only by the eect of F y can be considered as the bending deformation due to free end subjected to concentrated force load. So Eq.15 and Eq.16 can be deduced. EIyy = EI y = 1 F y x3 E 3 (15)

1 (16) F y x2 E 2 According to the principle of superposition, the total displacement of y E and B in the rectangular coordinate systems of the point O1 can be gained as follows. 1 1 3 EIyE = F x yE x2 E + F y xE 2 3 (17)

3.2.1. Model of wire lag not considering wire vibration between the two guide wheels In the MS-WEDM process, the wire electrode between the two guide wheels suers bending deformation because of the wire tension, the explosive force from gas bubbles, the plasma of the erosion mechanism, hydraulic forces due to ushing, electrostatic force and electrodynamics force [10]. In addition, this wire deection behavior is inuenced by the temperature increment in the discharge channel. Fig.11 illustrates the 9

1 EI B = F x yE xE + Fy x2 (18) E 2 While wire electrode is moving in the actual MS-WEDM processing, the component forces (F x and F y ) at the E section can be achieved according to the method of dynamic equilibrium and momentum theorem of steady ow.

bending deformation of wire electrode between the two guide wheels. Due to the wire in the non-discharging area without lateral loading, the wire can be considered as the straight line, while wire in the discharging area can be regarded as a curved girder. Thus the model of wire trajectory can be simplied as following assumes. 1. Workpiece is symmetrically set between two guide wheels. 2. The axial tensile force (T ) remains constant between the two guide wheels, and the wire mass is uniformly distributed along its length[17]. 3. According to the summary of section 2, the electromagnetic force and dielectric uid viscosity force can be ignored, and temperature increment on the wire lag leads to the variation of Youngs modulus. 4. Discharge resultant force action on the wire electrode is the main cause of wire deformation, and it can be regarded as a distributed force acting on per unit length of the wire, and the direction of this force is opposite to the cutting direction[2, 3, 9, 10, 17]. According to the above simplication, wire in the discharging area can be regarded as a curved girder with mobile hinged joints [2, 3, 9, 10, 17]. In the Fig.12, two hinge points (with lateral deformation and without perpendicular deformation) are set on the two ends of workpiece, and the each hinge point is subjected to perpendicular force from the component force (F y = qh/2) of wire tension. Hence, the general dierential equation of movement for a stretched string of length (L) in a plane (along the x axis) can be expressed as Eq.25. T 4 y 2 y y 2 y E(T ) I 4 = S 2 + + q( x,t) 2 t x x t (25)

Figure 11: Wire bending deformation between the two guide wheels

The term T (2 y/ x2 ) represents the force caused by wire bending deection due to wire tension (T ), and the term E(T ) I (4 y/ x4 ) indicates the force resulted in restraining transverse bending because of wire electrode rigidity, and the term S (2 y/t2 ) and (y/t) express the inertia force and damping force, respectively. In the practical machining, the wire tension T (1030N) is 20100 times larger than the wire inertia force (0.30.5N) due to tiny and slender characteristic of wire electrode, so the wire inertia force can be ignored. The eect of the damping force mainly reects the wire vibration behavior. If the wire in the discharging area is only subjected to distributed resultant force, the dierential equations of deection curve can be derived as Eq.26 and Eq.27. E(T ) I y 1 3 1 1 = qx qhx2 + qh3 x 6 4 24 (26) 10

Figure 12: Wire bending deformation in the discharging area

1 4 1 1 qx qhx3 + qh3 x (27) 24 12 24 The maximum deection y max can be obtained at the point of x = h/2. E(T ) Iy = ymax = 5qh4 384E (T ) I (28)

The maximum rotation angle can be gained at the point of x = 0 or x = h. max = qh3 24E (T ) I (29)
Figure 13: The bending moment analysis of innitesimal unit of wire

According to the Eq.27, it can be concluded that the equation of deection curve is the fourth-order function when wire is only subjected to distributed resultant force. Thus, when the wire is subjected to distributed resultant force and wire tension, the wire deection in the discharging area can be described by the method of fourth-order function tting as Eq.30. Considering the symmetry of wire trajectory, the maximum deection (ymax = y2 ) is acquired at the point of x=h/2, and the maximum rotation angle is gained at the point of x=0 or x=h. y = ax4 + bx3 + cx2 + dx + e (30)

At the point of x=h: y = y2 = 125qh4 9600E (T ) I + 976T h2 (35)

At the point of x=0,taking the derivative of x: E(T ) I 8y2 T h qh3 y = + x 25 24 5qT h5 y qh3 = 2 I 2 + 122 E IT h2 x max 24E (T ) I 1200E ( (T ) T) (36) (37)

max =

a, b, c, d, e are undetermined coecients, and they can be worked out by the below boundary conditions. Boundary conditions as below: When x = 0, y = 0, 2 y/ x2 =0; When x = h, y = 0, 2 y/ x2 =0; When x=h/2, y=y2 ; So y and y/ x can be deduced as Eq.31: y = ax4 2ahx3 + ah3 x = 16y2 x4 32y2 x3 16y2 x + 5h 5h4 5h3 (31)

Because the wire in the non-discharging area is considered as a straight line, the wire deection y 1 can be worked out as Eq.38. y1 = lmax = 5qT lh5 qlh3 2 I 2 + 122 E IT h2 24E (T ) I 1200E ( (T ) T) (38)

y = 4ax3 6ahx2 + ah3 (32) x In the Fig.13, the analysis of innitesimal unit of the wire has been conducted. Then bending moment equation can be gained as Eq.33. dM = T (4ax3 6ahx2 + ah3 )dx + qx (33)

From the Eq.35 and Eq.38, the wire deection has the positive correlation with distributed resultant force (q), workpiece thickness (h) and the distance (l) from workpiece to guide wheel, while the wire deection has the negative correlation with wire tension (T ), wire speed (v), exural rigidity (E (T ) I ) and section area (S ). In addition, the Youngs modulus of the wire electrode has a decreasing trend with the increase of the temperature in discharge channel according to Fig.9.

3.2.2. Model of wire vibration behavior between the two guide wheels The wire vibration is a very complicated phenomenon because the discharge condition, number of discharge spark and location of the discharge force acting on the wire are random in nature, and its behavior can be inuenced by the wire tension, discharge reaction force, damping force of uid and cutting feedrate, etc. The geometric accuracy of workpiece (taper error, corner error and kerf width) is mainly inuenced by wire vibration in machining thin workpiece. In this subsection, a model of wire electrode vibration is 11

Through four integrating processes and the limit of boundary conditions, the nial equation of deection curve can be derived as Eq.34. E(T ) Iy = 8y2 T x6 8y2 T x5 8y2 T x3 8y2 T hx + 15h 25 75h4 25h3 1 4 1 1 3 3 + qx qhx + qh x 24 12 24

(34)

developed under single discharge, and a theoretical solution of vibration equation is solved by the method of variables separation. Firstly, the wire electrode can be regarded as a plumb line in the cutting section, and the vibration behavior can also be treated as string vibration according to the classical vibration theory. Secondly, in the stable machining process, there is enough time to allow the wire electrode to vibrate hundreds of times, and the forced vibration can be ignored. So the amplitude of wire vibration in each cutting section is about the same. Thirdly, the main cause of wire vibration is the discharge impact force (F p (t)) under the single discharge, and the discharge impact force (F p (t)) at one spot can be simplied as Eq.39. F p (t) = n s Fd (t) (39)
Figure 14: The top view of cutting kerf width

For simplication, the following basic assumptions are required in order to obtain the amplitude of the wire vibration. 1. The wire electrode is slender, exible and not moving. 2. Workpiece is symmetrically set between two guide wheels. 3. The axial tensile force (T ) remains constant between the two guide wheels, and the wire mass is uniformly distributed along its length. According to the classical vibration theory, the string vibration equation at spot can be expressed as Eq.40. y 2 y 2 y + F ( t )( x ) = S (40) p t x2 t 2 This string vibration equation can be solved by variables separation method and boundary conditions as follows. = 0 y y ( x,0)=0 (0,t) y y =0 =0 T
(L,t)

On the basis of Eq.43, it can be seen that the Y max is direct proportion to the discharge impact force (F p (t)), and it also has a decreasing trend with the increase of wire tension (T ), the span of two guide wheels (L) and damping co-ecient (). In addition, the coecient (e (/2)t ) suggests that the maximum amplitude will attenuate with time. Because the discharge spot on the wire electrode is stochastic in nature, the maximum vibration amplitudes in all directions are about the same. As shown in the Fig.14, the kerf width (D F ) can be obtained by Eq.44. Hence, the maximum amplitude of wire vibration can be obtained by measuring the kerf width. Ymax = A = DF 2r 2d1 (44)

Theoretical solution of vibration equation is shown as Eq.41 and Eq.42. 2nF d y( , x, t) = L n =

n=1

x ( x,0)

n x e(/2)t n ) sin( ) sin(n t) sin( n L L

(41) 3.2.3. Superposition of maximum lag (y 1 + y2 ) and vibration amplitude (Ymax ) According to analysis in subsection 3.2.1 and subsection 3.2.2, the maximum wire lag (y 1 + y2 ) and wire vibration amplitude (Ymax ) occur at point of the wire electrode simultaneously. Hence, the maximum wire deection(W max ) can be obtained by superposition of maximum lag (y 1 ,y2 ) and vibration amplitude (Ymax ) based on vector superposing method in MS-WEDM, as shown Eq.45. Wmax = y1 + y2 + Ymax 12 (45)

n2 2 T 2 2 (n = 1, 2, 3, 4...) 2 L2 42

(42)

The maximum amplitude of vibration occurs at the middle plane of the workpiece ( x=L/2), and it express as Eq.(43).

Ymax = 4n s Fd
n=1

1 4n2 2 T 2 2 L2

e(/2)t (n = 1, 3, 5...) (43)

4. The conrmation experiment In this conrmation experiment, the discharge breakdown distance(d1 ) is 2m when the pulse voltage is 100V, the wire electrode diameter (2r) is 180m and the metrical data of kerf width ranges from 185m to 186m in machining 20mmthickness workpiece. This fact means that the maximum amplitude of wire vibration is about 12m according to Eq.44. This conclusion is consistent with the research result of Mohri N. and Puri A. B.[1, 18, 19]. The wire deection is the main cause to decrease the geometric accuracy in machining thick workpiece, while the wire vibration is the main factor of reducing the geometric precision in cutting thin part. This phenomenon is attributed to large specic damping co-ecient () in machining thick workpiece and small specic damping co-ecient () in cutting thin part. In other words, the wire vibration is an insignicant eect on machining accuracy in machining thick workpiece.

4.3. Experiment steps and results 1. The workpiece is set symmetrically between two guide wheels, and wire electrode has been kept perpendicular to workpiece. 2. By the method of control variables, dierent processing factors are set as table 3, and the other processing parameters remain constant: pulse voltage 100V, pulse-on time 50s, pulseo time 250s, wire speed 10m/s, track coecient 45. 3. Fig.15 shows that cut processing is conducted along the L1 (+y) direction to gain a reference plane parallel to the wire electrode, and a new workpiece coordinate system (O is the origin of coordinate) is established in each group experiment. 4. In No.1-5 and No.11-20 experiment, 3mm-cutting is conducted along the L 2 direction(- x) as Fig.15 (means the deection y0 direction and the deection y 1 direction are the same) at the beginning coordinate point (0, 5.000, 0)mm, and then cut o the pulse power suddenly and withdraw the wire electrode. On the reverse side to the reference plane, beginning with the coordinate point (-5.000, 5.090, 0)mm, the specimen is cut down along the L3 direction (+ x) (the opposite of the L 2 , means the deection y0 and the deection y 1 are in opposite directions), and the wire deection at the edge of specimen is y 0 +y1 . 5. In No.6-10 experiment, 3mm-cutting is conducted along the L3 (+ x) direction at the beginning coordinate coordinate point (0, 5.000, 0)mm and then cut o the pulse power suddenly and withdraw the wire electrode. On the reverse side to the reference plane, beginning with the coordinate point (+5.000, 5.090, 0)mm, the specimen is cut down along the L 2 (- x)direction, and the wire deection at the edge of specimen is |y 1 y0 |. 6. Along the Z direction of specimens, the distance from the edge of cutting mark to the reference plane is measured every 1mm interval by KEYENCE VH-Z500R (a high accuracy digital microscope). The measurement results (No.1-20) are shown in the table 4, and the cutting surface of No.4 sample amplied 400 times with the microscope is shown in Fig.16.

4.1. Experimental equipment and conditions This conrmation experiment was carried out on a high-end MS-WEDM with maximum output current of 5A, maximum wire feed rate of 20m/s, surface roughness less than 1.0m, (Dongguan Hustinova Precision Machinery Co., Ltd, China). Workpiece thickness of 20mm and molybdenum wire of 0.18 mm diameter were used for all experiments. In addition, the workpiece is a SKD-11 (Cr 12 MoV) steel block, which is a high carbon high chromium alloy steel used in the production of dies, plastic injection molding dies, precision gauges, spindle, jigs and xtures, etc.

4.2. Experiment theory The distributed resultant force (q) are in direct proportion to the discharge energy (E (t) )[20]. In order to obtain the value of E(t) , statistical analysis of the voltage and current of the process must be carried out. E (t) can be nally calculated using Eq.46 according to the description of Plaza, S.[20] E(t) =
0 tp

5. Analysis and discussion U(t) I(t) dt (46) 5.1. The analysis of the model of wire deection in the area near the guide wheel According to the model of wire deection in the area near the guide wheel, the parameters (wire tension(T ), wire radius (r), guide wheel radius (R) and wire speed (v)) are independent variables, and the inuence trends of these parameters on the wire deection can be obtained by the methods of control 13

According to the Eq.46, if pulse voltage, pulse-on time and pulse-o time remain constant in the machining process, q and E(t) will be both in direct proportion to the discharge current I(t) . Thus, q can be expressed as the simplied model Eq.47. q = kq I(t) (47)

Figure 16: Observation picture of the cutting surface of Sample 4

variables and numerical calculation.

5.1.1. The analysis of relationship of wire deection and four parameters Fig.17(a) shows the relationship of wire tension(T ) and wire deection(y0), and other parameters: E = 3.29 10 11 Pa, r = 0.09 mm, R = 15 mm, = 1.028 10 4 kg/m3, v = 10 m/s. The wire tension is the main reason for keeping the wire intertwined at two guide wheels and wire deection falls down dramatically with the increase of wire tension. However, the wire tension cannot be increased without limit in the actual machining which aims to avoid wire rupture, and it will be suitable when the wire tension ranges from 2030N. Moreover, to keep the wire tension constant plays an important role in maintaining high precision the MS-WEDM process, because dramatic uctuation of wire tension will result in signicant change of wire deection and wire vibration, which has the extremely bad impact on the performance of MS-WEDM process. Fig.17(b) shows the relationship of wire radius (r) and wire deection (y0 ) and other parameters: E = 3.29 10 11 Pa, T = 20 N, R = 15 mm, = 1.028 10 4 kg/m3, v = 10 m/s. Wire deection soars up signicantly with the increase of wire radius due to the increase of exural rigidity EI . The acceptable wire radius should be less than 0.1mm, and in this case, the wire deection is under 80m in the area near the guide wheel in MS-WEDM. Fig.17(c) shows the relationship of guide wheel radius (R) and wire deection (y 0 ), and other parameters: E = 3.29 10 11 Pa, T = 20 N, r = 0.09 mm, = 1.028 10 4 kg/m3 , v = 10 m/s. Wire deection drops gradually with the increase of guide wheel radius because of the increase of curvature k of the wire electrode in the area near the guide wheel. Fig.17(d) shows the relationship of wire speed (v) and wire deection (y0 ), and other parameters: E = 3.29 10 11 Pa, 14

Figure 15: Schematic diagram of cutting process

Table 3: Values of processing variables

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

I(t) (A) 1 2 3 4 5 1 2 3 4 5 2 2 2 2 2 2 2 2 2 2

T (N) 20 20 20 20 20 20 20 20 20 20 10 15 25 30 20 20 20 20 20 20

h(m) 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.01 0.03 0.04 0.02 0.02 0.02

l(m) 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.03 0.04 0.06

Cut direction L2 L2 L2 L2 L2 L3 L3 L3 L3 L3 L2 L2 L2 L2 L2 L2 L2 L2 L2 L2

Table 4: The results of experiment No.1-20

Z 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 d1 d2 d3 1 2870 2872 2866 2864 2865 2860 2861 2863 2862 2862 2864 2863 2862 2861 2864 2865 2863 2865 2868 2866 2 2774 2776 2772 2768 2766 2769 2765 2763 2764 2766 2761 2762 2765 2763 2768 2758 2774 2779 2778 2780 3 2650 2640 2647 2649 2645 2637 2635 2638 2634 2631 2625 2630 2634 2632 2636 2639 2637 2640 2648 2647 4 2605 2604 2597 2593 2580 2589 2587 2584 2585 2583 2585 2587 2583 2585 2587 2599 2594 2598 2603 2601 5 2510 2512 2503 2501 2496 2493 2495 2498 2490 2487 2485 2491 2490 2496 2498 2495 2497 2502 2500 2511 6 2959 2957 2958 2959 2954 2955 2953 2952 2951 2953 2954 2952 2953 2955 2954 2957 2959 2963 2961 2960 7 2890 2891 2885 2887 2886 2884 2882 2878 2880 2878 2880 2879 2885 2882 2881 2883 2885 2884 2879 2886 8 2762 2760 2761 2761 2755 2758 2753 2747 2750 2742 2745 2751 2746 2748 2753 2780 2754 2753 2755 2759 9 2701 2695 2698 2699 2684 2694 2686 2684 2680 2673 2677 2685 2683 2684 2690 2694 2693 2697 2695 2703

NO. 10 2647 2645 2643 2639 2633 2627 2629 2624 2620 2623 2621 2628 2635 2638 2642 2630 2647 2652 2650 2653 11 2643 2641 2639 2635 2637 2639 2630 2628 2630 2626 2629 2630 2635 2637 2642 2641 2647 2645 2649 2647 16 17 18 2498 1990 2821 2489 1987 2822 2494 1985 2820 2493 1980 2817 2490 1983 2815 2485 1975 2817 2483 1974 2816 2480 1970 2813 2482 1965 2815 2481 1964 2810 2480 1970 2814 2475 1963 2812 2476 1962 2819 2472 1957 2815 2471 1958 2817 2474 1954 2819 2475 1953 2822 2479 1951 2828 2477 1954 2826 2479 1953 2827 2480 1955 2485 1957 2482 1962 2484 1958 2487 1959 2489 1962 2490 1964 2497 1969 2495 1967 2496 1968 1972 1978 1980 1982 1984 1993 1988 1989 1995 1998 355 304 220 202 120 503 1006 176 12 9 8 5 24 46 11 12 2700 2701 2698 2694 2690 2692 2686 2685 2687 2684 2683 2685 2682 2680 2683 2685 2680 2687 2688 2692 13 2783 2781 2780 2781 2778 2773 2779 2775 2771 2770 2772 2773 2771 2774 2776 2770 2774 2773 2780 2775 14 2797 2795 2796 2793 2791 2792 2794 2793 2792 2790 2787 2792 2794 2792 2790 2792 2790 2793 2792 2790 15 2880 2881 2879 2878 2875 2877 2878 2876 2874 2879 19 2787 2786 2780 2784 2783 2780 2781 2780 2782 2778 2779 2781 2780 2783 2784 2787 2785 2793 2790 2791 20 2747 2745 2746 2743 2742 2741 2740 2742 2737 2739 2743 2741 2742 2746 2745 2747 2744 2748 2751 2750

132 223 352 395 438 6 10 17 22 27 40 6

210 250 12 10

112 240 299 329 9 16 24 29 18

The distance d1 = y0 + y1 (m), d2 = |y1 y0 | (m), d3 = y2 (m)

15

Figure 17: The relationship plot of y0 and control factors. (a) wire tension(T ), (b) wire radius(r ), (c) guide wheel radius(R) and (d) wire speed(v)

Table 5: The results of No.1-10

No. I(t) (A) y0 + y1 (um) |y1 y0 |(um) y2 (um) y0 (um) y1 (um) y2 (um)

10

1 2 3 4 5 1 2 3 4 5 132 223 352 395 438 40 112 240 299 329 6 10 17 22 27 6 9 16 24 29 46 55.5 56 48 54.5 86 168 296 347 384 6 9.5 16.5 23 28

is 52m. The deection(y 0) is independent of the cutting direction and discharge condition, while it is as relevant to wire tension as y0 is in the theoretical model. When the wire tension is 20N, deection(y 0 ) in the theoretical model is 55.5m, and its relative error is just 6.7% compared with the experiment results. Hence, it can be conrmed that the theoretical model is reliable and reasonable.

T = 20 N, r = 0.09 mm, R = 15 mm, = 1.028 10 4 kg/m3 . Wire deection rises up slowly with the increase of wire speed due to the increase of inertial force of the wire. Hence, the wire speed is a nonsignicant parameter of wire deection in the area near the guide wheel.

5.2. The analysis of macroscopic mechanical model of wire deection between the two guide wheels The eect of temperature increment on wire Youngs modulus has been obtained at subsection 2.4, and the pulse current was set the same in the subsection 2.4 and the conrmation experiment. Hence, corresponding pulse current and wire Youngs modulus can also be obtained from Tab.2. In addition, the exact value of discharge resultant force cannot be measured due to complicated discharge environment. From Eq.35 and Eq.38, the coecient (k q ) of distributed resultant force per unit current can be calculated by using the reverse problem method. Furthermore, the feasibility of our model is conrmed by comparison result the theoretical models with the experiment results and other researchers theoretical models. 16

5.1.2. The conrmatory analysis of model of wire deection in the area near the guide wheel The cutting direction(L 2) of No.1-5 experiment is opposite to the direction (L 3 ) of No.6-10 experiment under the corresponding currents, while the other parameters are T =20N, h=0.02m, l=0.05m. Then y 0 , y1 , y2 can be obtained as Tab.5. As the Tab.5 shows, it can be concluded that the deection(y 0) is an approximate constant, and the average value of y 0

5.2.1. The analysis of the macroscopic mechanical theoretical model According to the 20 groups experiment results and reverse problem method, the coecient (k q ) can be obtained by the method of interpolation and tting based on Eq.35, Eq.38 and Eq.47, and then the relative errors between the macroscopic mechanical theoretical model data and the experimental data can be worked out. In order to calculate the coecient (k q ) in this conrmation experiment condition, rst of all, the models of wire deection are assumed as Eq.48 and Eq.49. Secondly, by the method of nonlinear least-squares tting, the tting model can be deduced as Eq.50 and Eq.51 according to experimental data. Furthermore, in comparison with the experimental data, the average relative errors of wire deection (y 1 ) and wire deection (y 2 ) in the tting model are 9.30% and 10.48%, respectively. This fact means the tting model is reliable and appropriate. Then, the coecient (kq ) is calculated as 2.315N/(mA) by comparing the theoretical model (Eq.35 and Eq.38) and the tting model (Eq.50 and Eq.51), and this value of the coecient (k q ) is applied to calculate wire deection (y 1 ) and wire deection (y2 ) in the theoretical model. Eventually, compared with the experimental data again, the average relative errors of wire deection (y 1 ) and wire deection (y 2 ) in the theoretical model are 10.11% and 12.12% respectively, which means macroscopic mechanical theoretical models are reliable and feasible too. y2 = y1 = y2 = y1 = k1 I(t) h4 k2 E(T ) I + k3 T h2 k5 I(t) T lh5 k4 I(t) lh3 E(T ) I k6 (E (T ) I )2 + k7 E(T ) IT h2 298I(t) h4 29649E (T ) I + 1006.5T h 2 10.6914I (t)T lh5 0.1163I (t)lh3 E(T ) I 571.18(E (T ) I )2 + 93.46E (T ) IT h2 (48) (49) (50) (51)

reliable and reasonable, and the inuence trends of factors on wire deection agree with the practical machining. Moreover, the calculated results of wire deection (y 1 and y2 ) in our macroscopic mechanical theoretical models are closer to experimental data than other researches model on the basis of the less average relative errors.

6. Conclusions and future work The following conclusions can be drawn from the above investigation: 1. Some causes of wire deection have been analyzed to understand the fundamental mechanism of wire deformation, and the discharge resultant force and temperature increment prove to be the main causes of wire deection according to a detailed analysis of each causes. 2. Two macroscopic mechanical models of wire deection have been developed in the area near the guide wheel and between the two guide wheels considering temperature increment in machining 20mm-thickness workpiece process, respectively. The former model has been conrmed that the deection(y 0 ) is an approximate constant when the wire tension remains unchanged, and MS-WEDM will be more stabilized when the wire deection y 0 and y1 are in the dierent direction. In addition, compared with other models, our second macroscopic mechanical models turn out to be reasonable, and it can be concluded from the results of conrmation experiment that our models are more appropriate and practical than other researchers models 3. According to the two macroscopic mechanical models of wire deection, some practical approaches can be proposed to control the wire trajectory, such as decreasing the wire radius (r) and the span (L) of two guide wheels, employing the pulse generator with lower single pulse discharge energy and higher discharge frequency, and increasing the wire tension (T ). In the future work, these high-precision models of wire deection can be used for analyzing the corner error, taper error and other geometric accuracy. Moreover, they can be applied to set a lead compensation for wire deection into NC system.

5.2.2. Comparison with other researchers models Luo, Y. F. [9] established a new practical model, an arc tting, to calculate the wire bow error. While Puri, A. B. and Dauw, D. F. [2, 10] presented a new approach, a parabolic tting, to describe the wire trajectory. But there was no experiment to conrm their models in their researchers. In this subsection, using similar analysis method and experimental data from section 4, the comparing results of our models, Luos model and Puris models are illustrated Tab.6 and Fig.18. They suggest that the models of three authors research are 17

7. Acknowledgement This research is mainly supported by the National Natural Science Foundation of China (NSFC) under Grant No. 51175207 and Grant No. 51121002. In addition, National Key Technology R and D Program No.2012BAF13B07 and Science and Technology Planning Project of Guangdong Province

Table 6: The comparison of three models and experimental data

Our macroscopic mechanical models Deection Theoretical model Fitting model kq (N/(m A)) Fitting errors Theoretical errors 10.48% 12.12% y2
125qh4 9600E(T ) I +976T h2 298I(t) h 29649E(T ) I +1006.5T h2
4

Luos model y2
qh4 384E(T ) I /5+8T h2 298I(t) h4 29649E(T ) I +1006.5T h2

Puris model y2
qh2 8T 0.2738I(t) h2 T

y1
qlh3 24E(T ) I 0.1163I(t) lh E(T ) I
3

y1
ql(h+l) 2T 0.5931I(t) l(h+l) T

5qT lh5 2 I 2 +122E 2 1200E( (T ) IT h T) 10.6914I(t) T lh5 571.18(E(T ) I )2 +93.46E(T ) IT h2

2.315 9.30% 10.11%

2.372 10.48% 18.50% 10.50% 23.74%

1.6883 39.02% 75.20%

Figure 18: The comparison results between three models and the experiment data

18

No.2012B011300015 both aid this study. References

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ogy, 1998, 47(1): 173-176. [20] Plaza, S., Ortega, N., Sanchez, J. A., Pombo, I., and Mendikute, A. Original models for the prediction of angular error in wire-EDM taper-cutting. The International Journal of Advanced Manufacturing Technology 44.5-6 (2009): 529-538.

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