Investigation of Situational Correlations of Wire Electrical Discharge Machining of Superhard Materials with Acoustic Emission Characteristics

Abstract

The purpose of this research is to find relationships between the parameters of the acoustic emission signals accompanying the electroerosive processing with a wire electrode of metals and hard alloys and the most important process indicators. These indicators include an increase in the concentration of erosion products in the interelectrode gap, an increase in the probability of wire electrode breakage, the efficiency of the supplied energy, the current productivity. This article presents the results of the study of acoustic emission signals during the processing of hard alloys with a cutting machine. The main focus is on the period preceding the breakage of the wire electrode. Changes in the parameters of acoustic emission a few seconds before failure are shown, and the possibility of preventing wire breakage by monitoring the parameters of acoustic emission signals is established. To evaluate the efficiency of the energy supplied to the processing zone, a dynamic model is proposed, with the help of which the processing efficiency is estimated by changing the transmission coefficients in one or several frequency ranges. To explain the situation that occurs in the processing zone with an increase in the concentration of erosion products, the article draws a parallel between electroerosive and laser processing, related to technologies of processing with concentrated flows of energy. Studies have shown that acoustic emission signals can be used to search for rational processing modes and improve automatic control systems for electroerosive equipment.

Keywords

• wire electrical discharge machining
• metals
• hard alloys
• acoustic emission
• vibroacoustic diagnostics
• monitoring