Nonlinear dynamics analysis of multi-cutting wire electrode in WEDM-HS subjected to working fluid considering the effect of debris.

A reasonable dielectric fluid velocity and better exclusion of debris are very important to obtain a stable machining performance in multi-cutting of WEDM-HS. We investigated the dynamic characteristics of multi-cutting wire electrode in WEDM-HS subjected to working fluid considering the effect of debris. First, a fluid-solid coupling nonlinear vibration model is derived by analyzing the forces acting on the multi-cutting wire which locate in the dielectric fluid. The additional axial force arising from the transverse vibration of the multi-cutting wire is considered as a nonlinear term in the model. Considering that the debris accumulation in discharge gap severely influences the stability of multi-cutting wire electrode, the relationship between the debris volume concentration and debris-working fluid two-phase flow drag coefficient is obtained using the Einstein two-phase flow viscosity theory. Finally, the influences of several parameters on the multi-cutting wire displacement are discussed in detail. [ABSTRACT FROM AUTHOR]