Non-pulsed Energy Modeling Based on Energy Consumption Subunits in Wire Electrical Discharge Machining (WEDM) Process

The scientific and reasonable prediction of energy consumption in WEDM process is the key for energy-saving optimization of wire-cutting process in the design stage. The existing research about WEDM energy-saving studies mainly focus on the pulsed power control strategies. And, the research on non-pulsed energy consumption of WEDM is deficient. The non-pulsed energy consumption takes up a larger proportion in the whole WEDM process through theoretical analysis and case verification, and the energy consumption characteristics are equally representative. Therefore, the paper analyzes the energy characteristics based on non-pulsed energy consumption subunits of WEDM. A non-pulsed auxiliary energy consumption and feeding energy prediction model is established, and a WEDM machine tool is used for the experiment. The accuracy of the prediction model proposed in this paper can reach more than 96%. The raise and establishment of the model provides the basis for energy saving optimization of the subsequent wire cutting process.