Effect of no-load rate on recast layer cutting by ultra fine wire-EDM

Via material erosion in wire electrical discharge machining (WEDM), recast layers form on the surfaces of workpiece. In addition, ultra fine Wire-EDM can be usually cut once. To reduce the thickness of the recast layer as much as possible, the wire electrical discharge-electrochemical machining (WEDCM) method was proposed, which is based on the micro conductivity of the dielectric and microelectrolytic characteristics by adjusting the no-load rate of the pulse in the machining process. Furthermore, a state discrimination and servo control system based on discharge current was designed. The experiment results of different no-load rates show that the electrolytic effects increase as the no-load rate increases, and the main machining process is spark discharge erosion with a no-load rate in the range of 10% to 80%. At 90% no-load rate, the amount of recast layer formation in the forward direction of the wire electrode is almost the same as that of electrolytic dissolution, and it can be practically processed without a recast layer. Compared with 10% no-load rate, the kerf width only increases by 7.5%.