Adjei-Yeboah Joshua, Jahan Muhammad Pervej
Department of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH 45056, USA.
Micromachines (Basel). 2025 Apr 30;16(5):547. doi: 10.3390/mi16050547.
Wire electrical discharge machining (WEDM) enables the production of complex parts with tight tolerances, although maintaining dimensional accuracy in corners and tapers remains challenging due to wire deflection and vibration. This study optimizes WEDM parameters for achieving high accuracy in machining complex geometrical parts and taper cuts in 6061 aluminum alloy using an Excetek W350G WEDM machine with a copper wire electrode. Parameters including wire tension, pulse on-time, pulse off-time, wire feed rate, open circuit voltage, and flushing pressure were varied using a L18 Taguchi orthogonal array and the response graph method to identify optimal cutting conditions. Experimental results indicated that feature-specific optimization is crucial, as different geometrical features (rectangular fins, triangular fins, gears) exhibited varying critical parameters. Key findings highlighted the importance of wire tension and pulse on-time in maintaining cutting accuracy, although at varying levels for specific features. Response graphs demonstrated the effects of major WEDM parameters on corner and profile accuracies, whereas Taguchi analysis provided the optimum settings of parameters for each feature and taper cutting. These findings will help enhance precision, efficiency, and versatility of the WEDM process in machining complex profiles and corners, contributing to precision manufacturing.
电火花线切割加工（WEDM）能够生产出公差要求严格的复杂零件，不过，由于电极丝的偏转和振动，在拐角和锥度处保持尺寸精度仍然具有挑战性。本研究使用配备铜丝电极的Excetek W350G电火花线切割机床，对电火花线切割加工参数进行了优化，以在加工6061铝合金的复杂几何零件和锥度切割时实现高精度。使用L18田口正交阵列和响应图法改变包括电极丝张力、脉冲导通时间、脉冲关断时间、电极丝进给速度、开路电压和冲洗压力在内的参数，以确定最佳切割条件。实验结果表明，特定特征的优化至关重要，因为不同的几何特征（矩形翅片、三角形翅片、齿轮）表现出不同的关键参数。主要发现突出了电极丝张力和脉冲导通时间在保持切割精度方面的重要性，尽管针对特定特征的程度有所不同。响应图展示了主要电火花线切割加工参数对拐角和轮廓精度的影响，而田口分析则为每个特征和锥度切割提供了参数的最佳设置。这些发现将有助于提高电火花线切割加工复杂轮廓和拐角时的精度、效率和通用性，推动精密制造的发展。
