Wire tension in high-speed wire electrical discharge machining

This paper investigated the wire tension change in high-speed wire electrical discharge machining (HSWEDM). The symmetry of the wire-winding mechanism and the resistance to the wire electrode on the upper and lower guide frames were considered the main causes of a non-even wire tension. Combined with the simulation model and the redesigned wire-winding mechanism, the adjusting wheel and the protection block were used to control the symmetry of the wire-winding mechanism and the resistance to the wire electrode on the upper guide frame. The wire tension was found to be capable of remaining stable in the machining process. The redesigned wire-winding mechanism can improve cutting stability and efficiency in large thickness cutting processes as well as the consistency of workpiece dimension in multi-cutting processes.