Modeling and Simulation of Crater Formation and Wire Vibration in Micro WEDM

Abstract

This thesis proposes a modeling approach based on experimental study and a simulation system of the micro WEDM process that incorporates more detailed understanding of the crater formation process. The proposed model consists of three interacting parts of the machining process: wire vibration, discharge process and crater formation. Simulation using the proposed model predicts wire vibration pattern and machined workpiece surface as well as the location of sparks. The shape of craters are experimentally studied and characterized. Geometric models are developed to better represent the geometrical features of craters. A method is devised to construct overlapping craters from generic models of single craters. New features are incorporated into the WEDM process model. The influence of machining conditions on the various aspects of the machining process is analyzed. Simulation results indicate a linear relationship between workpiece profile error and wire vibration.