Study of the Machining Shape Monitor in Wire EDM

The quantitative relationship between the discharge power and the machining shape of a workpiece in wire electrical discharge machining (wire EDM) is discussed. The machining gap length is significantly related to the input current under various flushing conditions. We propose a new scheme for predicting the machining shape by monitoring the discharge currents at several positions on the workpiece. This scheme is expected to contribute to the development of a machining shape monitor using in-process wire EDM and to the improvement in straightness accuracy by adjusting subsequent processing conditions for the predicted machining shape.