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Improving RT-WEDM performance with a radio frequency signal monitoring system

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Abstract

The gap discharge state monitoring system for wire electrical discharge machining (WEDM) has an important impact on machining performance. Due to sampling noise and the slight differences between different types of discharge pulses in reciprocating traveling WEDM, it is easy to misjudge discharge pulse types based solely on the gap voltage and current in the conventional discharge state monitoring system. To provide more accurate feedback signals and achieve better machining performance, this study proposes to monitor gap discharge states using radio frequency signals. Radio frequency signals are analyzed in both the frequency and time domains. After determining the range of radio frequency signals through frequency domain analysis, radio frequency signals in a specific frequency range are amplified after filtering out noise and undesired signals. In addition, for sampling convenience, the radio frequency signal is processed using an envelope detection circuit for frequency down-conversion. In the time domain analysis, the available radio frequency signal is obtained and analyzed for different types of discharge pulses. Based on an ISO-pulse power supply, the characteristic analog radio frequency signal is used to classify the discharge pulses. The radio frequency signal monitoring system is then used to provide feedback signals for the servo feed rate control system. The experimental results indicate a substantial improvement in the classification accuracy. The material removal rate is improved by about 10% in roughing, and the surface quality is improved slightly.

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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

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Acknowledgements

The authors gratefully acknowledge the Suzhou Mecontronics Corporation for their kind assistance in this project.

Code availability

This paper uses proprietary software and will be not available.

Funding

This research is financially supported by the National Natural Science Foundation of China (Grant No. 51775341 and Grant No. 52075333), National Science and Technology Major Project (2018ZX04005001), and Shenzhen Basic Research Program (Grant No. JCYJ20170811160440239).

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Authors and Affiliations

  1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Zi-Lun Li, Xue-Cheng Xi, Hao-Yu Chu, Ling-Yi Xu, Qiang Gao & Wan-Sheng Zhao

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  1. Zi-Lun Li
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  2. Xue-Cheng Xi
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  3. Hao-Yu Chu
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  4. Ling-Yi Xu
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Contributions

Zi-Lun Li: Conceptualization, methodology, software, validation, formal analysis, and writing-original draft and Editing. Xue-Cheng Xi: Funding acquisition, supervision, and writing-reviewing and editing. Hao-Yu Chu: Formal analysis and validation. Ling-Yi Xu: Formal analysis and software. Qiang Gao: Formal analysis and software. Wan-Sheng Zhao: Funding acquisition, supervision, and writing-reviewing and editing.

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Correspondence to Xue-Cheng Xi or Wan-Sheng Zhao.

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Li, ZL., Xi, XC., Chu, HY. et al. Improving RT-WEDM performance with a radio frequency signal monitoring system. Int J Adv Manuf Technol 118, 391–404 (2022). https://doi.org/10.1007/s00170-021-07983-7

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