Energy modeling and minimizing energy consumption control strategy of wire electrical discharge machining (WEDM) through electrical parameters

Estimating the energy model of machining process at the process design phase has been recognized as an effective method for energy-saving and emission reduction in manufacturing. Wire electrical discharge machining(WEDM) is a non-traditional machining and widely used in aerospace, automobile, medical, tool, and die manufacturing industries. In WEDM, energy consumption and energy efficiency are different with electrical parameter control strategy, and energy modeling and minimizing energy control strategy of WEDM are often ignored at process design phase. To bridge this gap in WEDM life cycle, an energy model of WEDM is established based on the requirements of low-energy consumption at process design phase. Moreover, a minimizing energy electrical parameter control strategy is recommended by calculating energy at the process design phase, which results in lower energy consumption and better energy efficiency compared with conventional strategy. In addition, it has great performance in reducing processing time. Significantly, based on the experimental investigations and thereafter analysis of the test results, the total energy consumption and processing time are reduced by 21.94% and 28.23%, respectively.