The skin-effect in ferromagnetic electrodes for wire-EDM
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Citations
Effect of Electrode Size on the Performances of Micro-EDM
High-performance wire electrodes for wire electrical-discharge machining – a review:
Effect of cryogenic treated brass wire electrode on material removal rate in wire electrical discharge machining
Effect of Conventional EDM Parameters on the Micromachined Surface Roughness and Fabrication of a Hot Embossing Master Microtool
Review of size effects in micro electrical discharge machining
References
Knowledge-Based System for Wire EDM
Related Papers (5)
Frequently Asked Questions (17)
Q2. What is the effect of the skin-effect on a copper wire?
The skin-effect results from eddy currents within the wire that counteract the current in the core, and forces the current to the surface of the wire.
Q3. What is the effect of the coating on the cutting speed of the wire?
Since the coating is substantially less electrical resistant than the steel core, most of the Joule heating power will be dissipated in the coating.
Q4. How much does the resistance of a steel wire increase at high frequencies?
For the steel wire of diameter 100µm the influence of the skin-effect is less, it yields an increase of the resistance by a factor 2 to 3, resulting in a value which is 30 times as high as a copper wire.
Q5. What is the disadvantage of a voltage source?
A voltage source delivers a current that depends on the load: impedance of the machine, the wire, the gap and the work piece, which is a disadvantage while compared to current sources, who are supposed to deliver a fixed current independently of the process’s impedance.
Q6. What is the effect of conductive coatings on steel wires?
It is also mentioned that conductive coatings out of non-permeable materials on top of steel wires lower the impedance even at high frequencies.
Q7. What is the frequency dependence of a wire’s inductance?
The frequency dependence of a wire’s internal inductance is approximately given by equation 5, with ξ given by equation 2.2πνL R0 ≈ ξ2 − ξ66 if ξ << 12πνL R0 ≈ ξ − 3 64ξ + 3 128ξ3 if ξ >> 1 (5)The wire’s inductance L0 at low frequencies equals µ 8π [7].
Q8. How can the inductance of a coated a-magnetic wire be calculated?
The internal inductance of a coated a-magnetic wire can be calculated by calculating the energy stored in the magnetic field inside the wire.
Q9. What is the effect of the skin-effect on the resistance of a steel wire at frequencies?
Since the resistance of a steel wire at the frequencies under consideration seems to be independent of carbon content, the 0.7%C wire can be chosen to profit from its higher tensile strength in precision applications [6, 8].
Q10. How much resistance does a wire have?
When calculated for a steel wire (0.7%C) with a 4 µm Zn-coating the D.C. resistance is 17.32 Ω/m, compared to 22.73 Ω/m without coating.
Q11. What is the effect of the skin-effect on the resistance of a steel wire?
Since all known coatings (Cu, CuZnx, Zn,...) are a-magnetic, the skin-effect can be neglected in the calculation of the resistance of the coating.
Q12. What is the resistance of a wire with a thick coating?
For thick coatings the D.C. as well as the high frequency resistances are comparable to those of plain brass wires, while the tensile strength of their cores stays considerably higher.
Q13. What is the effect of the Joule effect on the cutting speed of a plain steel?
This means that e.g. a plain steel wire with high resistance will be weakened and broken even at lower peak currents (erosion energy), and hence lower speed, than a coated steel wire which has low resistance.
Q14. How is the resistance of a steel wire calculated?
For a coating with outer radius ro and inner radius ri it is given byRcoating = 1σcoatingπ(r2o − r2i ) (4)The total value of the wire’s resistance is then found by assuming that the core of the wire is electrically parallel to the coating.
Q15. What is the effect of the skin-effect on the inductance of a steel wire?
The dropping of the inductance due to the skin-effect in steel wires, as explained in section 2.2.1, will be counteracted by using a thin conductive coating which is non-permeable (copper, brass, zinc, . . . ) in the same way the rising of the resistance in counteracted.
Q16. What is the effect of the skin effect on the wire?
It has been shown by the examination of the wire’s impedance, that the skin-effect becomes a predominant phenomenon in wire-EDM, while machining with ferro-magnetic wires.
Q17. What is the effect of the skin-effect on the resistance of a wire?
In this sense the resistance electrically parallel to the steel core is smaller and less able to lower the total resistance of the wire.