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

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Abstract

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.

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Abbreviations

\(P_{NC}\) :

Power of CNC cabinet

\(P_{l}\) :

Power of lighting system

\(P_{cfs}\) :

Coolant supply system power

\(P_{tf}\) :

Motor power of taper feeding system

\(P_{wf}\) :

Power of wire feeding system

\(\emptyset_{X}\) :

Function between motor power and the feeding rate in X direction

\(\emptyset_{Y}\) :

Function between motor power and the feeding rate in Y direction

\(\emptyset_{X - Y}\) :

Function between motor power and the resultant speed feeding in X, Y direction

\(\emptyset_{X \sim Y}\) :

Function between motor power and curve feeding rate

\(n\) :

Certain speed grade of wire feeding system

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Acknowledgements

The authors are very grateful to all the anonymous reviewers for the valuable opinions and suggestions on the improvement of our paper. This research is supported by the Natural Science Foundation of Zhejiang Province under Grand No. LY18E050007 and National Natural Science Foundation of China, No. 51505428.

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Authors and Affiliations

  1. School of Mechanical and Energy Engineering, Zhejiang University of Science and Technology, Hangzhou, 310023, China

    Jun Zheng, Xuwei Lai, Xingjian Zhou, Ankai Chen & Wang Zheng

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  1. Jun Zheng
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Correspondence to Jun Zheng.

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Zheng, J., Lai, X., Zhou, X. et al. Non-pulsed Energy Modeling Based on Energy Consumption Subunits in Wire Electrical Discharge Machining (WEDM) Process. Int. J. Precis. Eng. Manuf. 20, 853–862 (2019). https://doi.org/10.1007/s12541-019-00107-y

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