Observation and simulation investigation for the crater formation under discharge plasma movement in RT-WEDM

Observations of the discharge gap were conducted to investigate plasma motion in reciprocated traveling wire electrical machining (RT-WEDM). It was found that a continuously slides on surface workpiece. An oscillating moving heat source is proposed better describe characteristics motions. Based an source, novel thermal-fluid coupling model by adopting level-set method formation crater and effects parameters craters. Discharge sliding, latent heat, molten pool forces are comprehensively considered model. Simulation experimental results show sliding has significant effect crater. At end discharge, considerable proportion materials remains pool. A high speed can lead low aspect ratio thin recast layer. Due increase pulse duration significantly length decrease ratio, while peak current depth volume also morphologies simulated craters consistent, verifying feasibility accuracy simulation explaining mechanism RT-WEDM.