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Vibration modeling and analysis of wire during the WEDM process

ABSTRACT During the wire electrical discharge machining (WEDM) process, the vibrations of the wire generated by the gap force is the main cause of imprecision. To achieve more precise results with better accuracy, understanding of the vibration management of the wire is essential. In this article, the wire’s vibration behavior is introduced briefly, followed by an exploration of an equation, derived from Hamilton’s principle, which expresses the vibration of a wire moving axially. This equation is presented under some simplified assumptions. In addition, the relationship between the maximum amplitude of the vibration and the main relative variables is presented. The solution demonstrates that a thicker workpiece results in a larger amplitude of vibration, yet the axial speed of the wire has no impact on the maximum amplitude.