In this paper, firstly, the microscopic discharging conditions of reciprocated-WEDM (also known as HS-WEDM) are studied, based on the picture data that recoded by 30000 frame/s high-speed camera. The research shows that the instable and inefficient cutting of HS-WEDM is mainly due to the big discharging chips and badly chips removal conditions in the discharging channels. In order to solve these problems, based on nanosecond pulse and microsecond pulse superimposed discharging strategy, a double-frequency power supply with current limiting inductance is designed. And then particle size distribution tests are carried out. The experiments prove that the size of the discharging chips can be reduced, within the discharging process of the double-frequency power supply. And smaller chips are helpful for the chips removal. Finally, by using dielectric with better encapsulation and inclusive, the cutting efficiency of the HS-WEDM with double-frequency power is higher than 350mm2/min. The results show that the cutting efficiency mainly depend on the size of the chips and chip removal ability in the discharging channel. And the double-frequency power supply with current limiting inductance in this paper obviously improves the WEDM efficiency.
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