Influence of Single Discharge Impulse on Vibration of Tool Electrode in Wire Electrical Discharge Machining

This paper describes the behavior of wire vibration during continuous machining with respect to the action of impulse based on a single discharge. The impulsive force acting on a wire is given by an experimental result of transient wave forms caused by a single discharge with the consideration of the simulation result supposing a vibration system to be a beam. The mean displacement of the wire obtained from the observation of continuous machining does not always obey the resultant displacement calculated by superposition of impulses from a set of single discharges. The vibration model is studied using a nonlinear model in which the number of impulses acting on the wire depends on the instantaneous gap distance between the wire and the workpiece. Thus, the behavior of the wire is significantly affected by the amplitude of the wire due to its tension or machining feed rate and by the discharge interval.