Development of Simulator for Wire Electrical Discharge Machining

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In this research, we developed a WEDM (Wire Electrical Discharge Machining) simulation method which can reproduce the discharge phenomena of WEDM on computer accurately. The simulation process consists of searching for discharge locations, removing the workpiece and analyzing wire vibration. Since unclarified parameters such as ignition delay time, explosive force, damping coefficient, and permittivity of dielectric in simulation are difficult to measure from experiments, they were obtained by solving the reverse problem using parametric programming. With the parametric programming method, optimum parameters for simulation were searched simultaneously to minimize differences between simulation results and experimental results.In order to evaluate the simulation accuracy, simulation of finish cutting was performed using the parameters identified. It was found that high precision simulation of finish cutting can be realized with the simulation error less than 1.5μm.or the next step, simulation program for rough cutting was developed. Shapes of straight grooves and right angled grooves were cut, and then simulation results were compared with the experimental results. Changes in the straightness of both frontal and lateral surfaces of the grooves and the width of the grooves were investigated by increasing the feed rate and wire electrode tension. The results of simulation coincided qualitatively with the experimental results.