Machining of cylindrical parts by wire electrical discharge grinding using thin plate guide

In order to meet the processing requirements of precise cylindrical parts on hard and difficult-to-machine materials, this paper introduces wire electrical discharge grinding (WEDG) using thin plate wire guide for cylindrical parts machining. The spindle system and the wire transport system to realize this processing method was added to a low speed wire electrical discharge machining (LS-WEDM) machine tool. In order to realize the online measurement of the machining accuracy of the cylindrical parts, an online measurement system of two-degree-of-freedom based on laser displacement sensor was built. The reasons for the incomplete removal of the machined surface were analyzed. Through the application of a new tool setting strategy and reasonable selection of processing parameters, the phenomenon of incomplete processing can be avoided. The experimental research on the effects of part rotational speed, wire feed rate, wire running speed and wire tension on roundness, surface roughness Sa, and surface morphology were carried out. Finally, example of the cylindrical parts is given to verify the machining accuracy.