Vibration analysis of the wire tool in wire-cut EDM

Cutting with high accuracy is possible using wire electrical discharge machining or WEDM. Nonetheless, while machining parts, amplitude of vibration causes inaccuracy of cutting. The main topic of this research is investigating the factors affecting amplitude of vibration of the wire-tool in WEDM using mathematical governing equation of motion of wire electrode. Hence, machining and finding ways to reduce the amplitude of vibration is the main purpose of this research. The consequence of reducing amplitude of wire vibration is cutting with higher accuracy and having smoother finished surface. In this research, the governing equations of motion of the wire-tool vibration are obtained using the Euler-Bernoulli beam model, fixed at both ends and moving in axial direction. The wire undergoes different forces including the body force produced by electrical discharge, damping force caused by the dielectric fluid, thermal force produced in the machining area and the axial force. Thereafter, the partial differential equation of motion of the wire-tool is converted to an ODE equation using Galerkin's method and then it will be solved using fourth order Runge-Kutta method. The results of this research show that the amplitude of vibration can be decreased by increasing the axial force and the decreasing of electrical discharge frequency, wire length, temperature differences and reduction of the workpiece width. Also, the results show that increasing the temperature by 70 degrees in the axial force of 17.5N can lead to a 60% increase in the vibration amplitude of the wire. Also, the results show that increasing the temperature by 70 degrees in the axial force of 17.5N can lead to a 60% increase in the vibration amplitude of the wire.