Wire electrochemical machining using reciprocated traveling wire

Wire electrochemical machining (WECM) is a cutting process in which the workpiece acts as an anode and the wire as a cathode. WECM is typically used to cut plates and exhibits a great advantage over wire electro-discharge machining, namely, the absence of a heat-affected zone around the cutting area. The enhancement of WECM accuracy is a research topic of great interest. In WECM, the homogeneity of the machined slit has a decisive influence on the machining accuracy. This is the first study in which the integration of pulse electrochemical machining (ECM) and a reciprocated traveling wire electrode was used to improve the homogeneity of this slit. The experimental results show that the combination of pulse ECM and a reciprocated traveling wire electrode could enhance the accuracy of WECM and that generally a low applied voltage, pulse duty cycle, and electrolyte concentration; an appropriate traveling wire velocity; and a high pulse frequency and feeding rate enhance the accuracy and stability of WECM. Finally, a microstructure with a slit width of 177 μm, with a standard deviation of 1.5 μm, and with an aspect ratio of 113 was fabricated on a stainless steel substrate measuring 20 mm in thickness.