Simulation and experimental study of wire tension in high-speed wire electrical discharge machining

This study analyzes the tension of different wire electrode parts in the high-speed wire electrical discharge machining (HSWEDM) and builds a mathematical model of wire tension change. Combined with the mathematical model and the LabVIEW software, a simulation system of wire tension change is developed. And simulation results indicate that the phenomenon of non-even wire tension is observed under the condition with no discharging. Based on the simulation system, this study also analyzes the effect of each parameter on wire tension in HSWEDM and redesigns the reciprocating wire-winding system according to the analysis results. The experimental results suggest that the change trend of non-even wire tension can be effectively controlled in the redesigned system.