Influences of single-pulse energy distribution on WEDM cutting efficiency

In wire electrical discharge machining (WEDM), cutting efficiency is a significant process index whose improvement has always been the research focus. Among the many factors affecting cutting efficiency, discharge energy is the most important factor. Different energy distribution form pulses were obtained by changing the peak currents at single-pulse different discharge stages. Through single-pulse discharge experiments, pulse energy distribution how to impact discharge channel motion characteristics was studied. When the energy distribution is changed through gradually increasing the peak current, an outward-pointing pressure difference will be formed inside the channel, which provides a driving force for the channel to move faster, accelerating the material erosion rate and increasing the discharge crater surface size. The cutting results reveal consistent variations in the cutting efficiency and surface size of individual discharge crater with the pulse energy distribution form. Through changing single-pulse energy distribution, the cutting efficiency can be improved by about 21%.