Study on high-precision finishing by Wire-EDM

Micro-finishing by High-Frequency AC Source

Abstract

Substantive efforts have been directed to improving the performance of EDM over the last twenty yeays and new applications of EDM are being made at an increasing rate. The industrial application of Wire-EDM have been expanding rapidly and offering many new applications. As an example, there in an increasing industrial demand for micro-finishing of less than 1μm R_max surface roughness by Wire-EDMs to replace conventional jig-grinding operations and polishing processes. This paper describes a detailed research investigation on the use of a high-frequency AC power source for achieving submicron surface roughness based on theoretical analysis and experimental methods.
The current pulse duration of high-frequency AC power source can be extremely short in comparison with the DC power source and allows a submicron machined surface. Reducing the current energy, a high-gloss micro-finished surface of less than 0.2μm R_max has been achieved.