The Technological Quality Control Of Stack Cutting By Wire Electrical Discharge Machining

Electrical discharge machining (EDM) of a stack allows achieving high precision and quality of cut surfaces and, therefore, this method is indispensable for state-of-the-art mechanical engineering. The procedure of EDM is carried out with wire-cutting machines. The characterization of constructive parameters of a stack of material and applying of an efficient cutting regime are the most important preconditions providing high precision of EDM. The goal of this work is the improvement of quality and efficiency of wire electrical discharge machining (WEDM) technology by theoretical and experimental studies of the WEDM process. The subsequent development of theoretical and empirical models allowing for the calculation of the quality parameters of treated surfaces is realized. It is shown that the main characteristics of cut surfaces are the roughness, size precision, error profile and structure of a surface layer. For the first time, the regression dependencies between the main parameters of the WEDM process (pulse on-time ton, off-time toff, the height of the stack and the physicomechanical properties of the cut materials are obtained. The experimental study of WEDM confirms the results of mathematical modeling. It is proved experimentally that at an interlayer gap higher than 0.1mm, the cutting process stability is decreasing whereas the probability of the electrode fracture is increasing. However, it is found that at ton=21μs and toff=60μs, a stable cutting regime leading to bundling of the stock materials made from steel 65Γ can be realized.