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Development of the Cylindrical Wire Electrical Discharge Machining Process


 Results of applying the wire Electrical Discharge Machining (EDM) process to generate precise cylindrical forms on hard, difficult-to-machine materials are presented. The design of an underwater rotary spindle is first introduced. The spindle is added to a conventional two-axis wire EDM machine to enable the generation of free-form cylindrical geometry. Mathematical models for material removal rate and surface finish in cylindrical wire EDM of the free-form cylindrical workpiece are derived. Experiments are conducted for cylindrical and 2D wire EDM of brass and carbide work-materials. Comparing to the conventional 2D wire EDM of the same work-material, higher maximum material removal rates could be achieved in the cylindrical wire EDM. The surface finish and roundness of parts generated by cylindrical wire EDM at different part rotational speeds and wire traverse speeds are measured and analyzed.