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<p>To address the limitations of low efficiency in existing measurement methods for wire electrical discharge machining (WEDM), this study proposes an on-machine measurement method based on inter-electrode impedance (IEI). An on-machine measurement theoretical model was established based on the relationship between IEI and distance. Workpieces of different thicknesses, inclination angles, and materials were measured to determine the adaptability of the IEI method. Measurements on standard gauge blocks were performed to compare the repeatability and accuracy with the traditional probe-based method. The experimental results demonstrate that the IEI method achieves a measurement accuracy of ≤ 6&#xa0;μm and a measurement fluctuation error of ≤ 4&#xa0;μm, exhibiting good adaptability. Compared to probe-based measurement methods, the IEI method increases measurement efficiency by approximately 80% and enables the measurement of narrow gaps inaccessible to probes. This research provides a novel measurement method for WEDM technology, enhancing both measurement efficiency and adaptability while maintaining measurement accuracy.</p>

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A novel on-machine measurement method for WEDM based on inter-electrode impedance for efficiency improvement

  • 期刊论文

  • 发表日期：

    2026年3月7日

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  • Yilin Guan,
  • Fuzhu Han

摘要

To address the limitations of low efficiency in existing measurement methods for wire electrical discharge machining (WEDM), this study proposes an on-machine measurement method based on inter-electrode impedance (IEI). An on-machine measurement theoretical model was established based on the relationship between IEI and distance. Workpieces of different thicknesses, inclination angles, and materials were measured to determine the adaptability of the IEI method. Measurements on standard gauge blocks were performed to compare the repeatability and accuracy with the traditional probe-based method. The experimental results demonstrate that the IEI method achieves a measurement accuracy of ≤ 6 μm and a measurement fluctuation error of ≤ 4 μm, exhibiting good adaptability. Compared to probe-based measurement methods, the IEI method increases measurement efficiency by approximately 80% and enables the measurement of narrow gaps inaccessible to probes. This research provides a novel measurement method for WEDM technology, enhancing both measurement efficiency and adaptability while maintaining measurement accuracy.