Optimization of nozzle flushing method for smooth debris exclusion in wire EDM

Takuya Fujimoto, Akira Okada, Yasuhiro Okamoto, Yoshiyuki Uno

Research output: Chapter in Book/Report/Conference proceedingConference contribution

5 Citations (Scopus)

Abstract

In a wire EDM using a thin wire electrode, better exclusion of debris from the machined kerf is important in order to maintain stable machining performance, since the area of spark generation is along a line and very small. When large amounts of debris stagnate in the gap, secondary discharges possibly occur and these discharges easily concentrate on the same location, which leads to unstable machining performance, wire breakage, low machining rate and a low shape accuracy. Conventionally, the exclusion of debris is carried out by jet flushing with an upper and lower nozzle. However, the flow field of machining fluid in the kerf due to the jet flushing and the effect of jet flushing conditions from the nozzles on debris exclusion have not yet been sufficiently examined. This study aims to clarify the flow field in the machined kerf by computational fluid dynamics (CFD) and to propose new jet flushing methods for smooth debris exclusion in the wire EDM. The effects of workpiece thickness and machined kerf length on the flow field of working fluid in the kerf under conventional jet flushing conditions are discussed. Then, jet flushing with a tilting nozzle is proposed in order to decrease the debris stagnation area near the wire electrode. As a result, by using the tilting nozzle, removal rate can be improved because of the smooth debris exclusion.

Original languageEnglish
Title of host publicationKey Engineering Materials
Pages73-78
Number of pages6
Volume516
DOIs
Publication statusPublished - 2012
Event4th International Conference of Asian Society for Precision Engineering and Nanotechnology, ASPEN 2011 - Hong Kong, China
Duration: Nov 16 2011Nov 18 2011

Publication series

NameKey Engineering Materials
Volume516
ISSN (Print)10139826

Other

Other4th International Conference of Asian Society for Precision Engineering and Nanotechnology, ASPEN 2011
CountryChina
CityHong Kong
Period11/16/1111/18/11

Fingerprint

Debris
Nozzles
Wire
Machining
Flow fields
Electrodes
Fluids
Electric sparks
Computational fluid dynamics

Keywords

  • CFD
  • Debris exclusion
  • Flow field
  • Jet flushing
  • Wire Edm

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Mechanical Engineering

Cite this

Fujimoto, T., Okada, A., Okamoto, Y., & Uno, Y. (2012). Optimization of nozzle flushing method for smooth debris exclusion in wire EDM. In Key Engineering Materials (Vol. 516, pp. 73-78). (Key Engineering Materials; Vol. 516). https://doi.org/10.4028/www.scientific.net/KEM.516.73

Optimization of nozzle flushing method for smooth debris exclusion in wire EDM. / Fujimoto, Takuya; Okada, Akira; Okamoto, Yasuhiro; Uno, Yoshiyuki.

Key Engineering Materials. Vol. 516 2012. p. 73-78 (Key Engineering Materials; Vol. 516).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Fujimoto, T, Okada, A, Okamoto, Y & Uno, Y 2012, Optimization of nozzle flushing method for smooth debris exclusion in wire EDM. in Key Engineering Materials. vol. 516, Key Engineering Materials, vol. 516, pp. 73-78, 4th International Conference of Asian Society for Precision Engineering and Nanotechnology, ASPEN 2011, Hong Kong, China, 11/16/11. https://doi.org/10.4028/www.scientific.net/KEM.516.73
Fujimoto T, Okada A, Okamoto Y, Uno Y. Optimization of nozzle flushing method for smooth debris exclusion in wire EDM. In Key Engineering Materials. Vol. 516. 2012. p. 73-78. (Key Engineering Materials). https://doi.org/10.4028/www.scientific.net/KEM.516.73
Fujimoto, Takuya ; Okada, Akira ; Okamoto, Yasuhiro ; Uno, Yoshiyuki. / Optimization of nozzle flushing method for smooth debris exclusion in wire EDM. Key Engineering Materials. Vol. 516 2012. pp. 73-78 (Key Engineering Materials).
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