Wire electrical discharge machining applied to high-speed rotating workpieces

In order to evaluate the influence of high-speed rotating workpieces on wire electrical discharge machining (WEDM), single discharge experiments were carried out inside a grinding machine, in a self-designed wire electrical discharge dressing device (WEDD-device). The shape and size of eroded craters, measured on the workpiece/anode, were found to be highly influenced by the applied relative speed. Based on the crater's shape, its radial expansion speed can be calculated and the slip of the plasma arc column can be measured. Additionally, it was found that the volume of eroded craters increases as relative speed is increased, indicating that higher melting efficiencies are achieved for higher relative speeds. Finally, an electro-thermal model is described and simulation results are discussed, which help to better understand the influence of relative speed on erosion.