Fundamental study of the electrical and acoustic characterization of different types of single discharges in wire electrical discharge machining (WEDM)

在电火花线切割加工中，人们对不同类型的放电相互作用所产生的个体能量贡献缺乏基本的了解。此外，这些放电类型对材料去除和边缘区形成的影响在很大程度上是无法解释的。澄清这些相互关系将为有力地记录过程创造必要条件，以便获得认证所需的知识。研究假设如下：与线切割中的单次放电的手段，不同类型的放电可以具体地产生，精力充沛的特点，并可以描述其特定的去除processs.The工业线切割机的单次放电功能的实现和由此产生的跟踪连续过程的能力，回到其个人的贡献是研究方法的核心。通过这种方式，可以分别研究不同的放电类型，并精确表征它们对局部材料改性的影响。与不允许这种特定相关性并且仅能够对转换的能量和去除率进行一般分析的连续过程相比，可以使用单独的放电来建立对过程的基本理解，然后可以将其转移回连续过程。为此目的，必须实施用于在商业线EDM机器上产生单次放电的合适机制。在此基础上，可以首先研究标准排放的具体情况和影响变量。通过改变放电能量、材料和线材料，原则上可以表征先前不确定的线腐蚀特定现象。随后，开发了进一步的技术解决方案，不仅可以产生标准放电，还可以产生异常放电和短路。以这种方式，在连续工艺中占主导地位的条件被单独再现，并根据引入材料中的能量的量和所产生的单个材料去除来描述。为此，建立了一种组合的电和声过程信号的测量和评估方法，并对材料中的能量耗散进行了相对热分析。

In wire EDM, there is a lack of basic understanding of the individual energetic contributions made by the interaction of the different types of discharge that occur. In addition, the influence of these discharge types on material removal and rim zone formation is largely unexplained. The clarification of these correlations would create a necessary condition for the energetic documentation of the process in order to obtain the needed knowledge for certification. The research hypothesis is the following:With the means of single discharges in wire EDM, different types of discharges can be specifically generated, energetically characterized and their specific removal processes can be described.The implementation of the single discharge functionality for industrial wire EDM machines and the resulting ability to trace the continuous process back to its individual contributions is the core of the research approach. In this way, different discharge types can be investigated separately and their effects on the local material modification can be precisely characterized. In contrast to the continuous process, which does not allow this specific correlation and only enables a general analysis of converted energy and removal rate, individual discharges can be used to build up a basic understanding of the process, which can then be transferred back to the continuous process. For this purpose, a suitable mechanism for generating single discharges on a commercial wire EDM machine must be implemented. On this basis, the specifics of and the influencing variables on standard discharges can first be investigated. By varying the discharge energy, the material and the wire material, the previously uncertain wire erosion-specific phenomena can be characterized in principle. Subsequently, further technical solutions are developed to generate not only standard discharges but also abnormal discharges and short circuits. In this way, the conditions prevailing in the continuous process are reproduced separately and described in terms of the amount of energy introduced into the material and the resulting individual material removal. For this purpose, a measurement and evaluation methodology of combined electrical and acoustic process signals is established, and a relative thermal analysis of the energy dissipation into the material is carried out.