Study on wire electrochemical machining assisted with large-amplitude vibrations of ribbed wire electrodes

A large-amplitude vibration of wire electrode tool is introduced to enhance electrolyte renewal and bubble removal in wire electrochemical machining. It is verified via simulation and high-speed video that hydrogen bubbles generated in electrochemical reactions can be expelled effectively from the machining gap by means of large-amplitude vibrations and a better effect was obtained in the upward duration. A ribbed wire electrode is employed to intensify electrolyte renewal process due to its specific structure. The experimental results demonstrated that the proposed large-amplitude vibration and ribbed electrode significantly accelerate electrolyte renewal, thereby hastening material removal rate and improving machining efficiency.