First report of System Identification in Wire Electrical Discharge Machining

In this paper, the behavior of wire vibration in machining process is studied by using a system modeled on the basis of experimental results. For the purpose of examining the behavior of wire vibration, dynamical changes in the material removal process must be taken into account. Therefore, a machining system set up is modeled where the interference between the vibration system of the wire electrode and the material removal system are considered. In this system, the material removal rate and the external force output from the material removal system are the input of the vibration system, whereas, the gap distance output from the vibration system is the input source of the material removal system. In order to analyze the modeled system, some simulations of the machining process are carried out. In the analysis of these simulations, a statistical method is applied to the wire displacement. Furthermore, the mean value and the magnitude of a simulated wire displacement are quantitatively compared with the measured results. Using the modeled system, the relation between wire vibration and state variables in the system are clarified.