Plasma characteristics and material erosion mechanism in multi-channel wire electrical discharge machining  

作　　者：Guokang SU Chuanyun ZHANG Junfei LI Xiaolei CHEN Guixian LIU Yongjun ZHANG 

机构地区：[1]State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment,Guangdong University of Technology,Guangzhou 510006,China [2]Guangdong Key Laboratory of Advanced Manufacturing Technology of Marine Energy Equipment,Guangdong University of Technology,Guangzhou 510006,China [3]Guangzhou Key Laboratory of Nontraditional Machining Technology and Equipment,Guangdong University of Technology,Guangzhou 510006,China [4]School of Mechanical Engineering,Xi’an Technological University,Xi’an 710021,China

出　　处：《Chinese Journal of Aeronautics》2024年第10期508-525,共18页中国航空学报（英文版）

基　　金：Supported by the National Natural Science Foundation of China(No.51275098);National Natural Science Foundation of China(No.52375416);Natural Science Foundation of Guangdong Province(No.2023A1515012028).

摘　　要：Multi-channel wire electrical discharge machining(MC-WEDM)is an advanced and high-efficiency machining technology,but its material erosion mechanism remains unclear.In this study,dual-channel wire electrical discharge machining was utilized as a case study to investigate the impact of the plunging current on both the plasma characteristics and material erosion under complex discharge conditions.Force analysis was conducted on the charged particles in the plasma,revealing that the plunging current can influence the trajectory of the plasma by modifying the selfmagnetic field.The particle tracking method was employed to simulate the motion of electrons,revealing that in MC-WEDM,electrons exhibited a larger and more uniform distribution.The evolution of the plasma within a single-pulse discharge was observed using high-speed photography technology,and the discharge signals collected from different channels were analyzed.It was observed that the plasma in MC-WEDM experienced more intense back-and-forth sweeping on the workpiece surface,facilitating the ejection of molten metal from the molten pool.The oscillating plasma exhibits a larger processing area and a more uniform distribution of energy,resulting in the formation of larger and shallower discharge craters.Furthermore,the influence of the amplitude and time point of the plunging current on the volume and area of the discharge craters was summarized.Finally,MC-WEDM significantly reduced the occurrence of holes and micro-cracks and exhibited a thinner recast layer in the continuous discharge experiment.

关 键 词：Multi-channel WEDM Discharge observation Plunging current Plasma characteristics Material erosion Discharge crater 

分 类 号：TG484[金属学及工艺—焊接]