Abstract:

At present, the highest cutting efficiency of HSWEDM has been over 200mm2/min. However, the traditional pulse power only improved pulse energy in this situation, which will cause the molybdenum wire severely worn and may be broken in short time. According to the discharging waveform of the pulse power, the differences between the traditional pulse power and high efficiency, low wire wear pulse power were analyzed, meanwhile the discharge mechanism of the efficiency and low wire wear of pulse power was also researched. The research shows that, controlling the discharge current of the leading and trailing edge by the ladder pulse and cutting off the abnormal pulse promptly can reduce the wear of the wire electrode. On the other hand, equal energy pulse used in the process, can effectively improve the chance of discharge and utilization rate of pulse. Finally, the new type pulse power supply apparently increases the cutting efficiency, improves the surface roughness of work-pieces and realizes to cut steadily in the condition of 190~200mm2/min cutting efficiency.

Key words: high speed wire-cut electrical discharge machining (HSWEDM), efficient cutting, low wire wear, machining mechanism

摘要：

目前，高速往复走丝电火花线切割最高切割效率已突破200mm2/min，传统脉冲电源靠单纯提高脉冲能量来增加切割效率会导致钼丝损伤大、损耗加剧，短时间内就可能出现断丝。从脉冲电源的放电波形分析入手，分析了传统脉冲电源和高效低损耗脉冲电源的差异。研究认为，采用阶梯脉冲合理控制放电电流的前后沿，在加工中对非正常放电脉冲及时切断以减小对电极丝造成的损伤及损耗，采用等能量脉冲方式提高放电利用率等措施能大大提高切割效率，改善切割表面粗糙度，在切割效率190～200mm2/min条件下能实现长期稳定切割。

关键词: 电火花线切割, 高效, 低损耗, 加工机理