Study on micro reciprocating multi-wire electrical discharge machining

Study on micro reciprocating multi-wire electrical discharge machining | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Study on micro reciprocating multi-wire electrical discharge machining XIANG CHEN, Yukui Wang, Yuanming Zhao, Jiayi Deng, Cheng Guo, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8884933/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract This paper presents a high-efficiency and sustainable micro wire electrical discharge machining (micro-WEDM) method employing reciprocating multi-wire electrodes with 50 µm in diameter. To realize stable multi-channel discharge, two-roller, three-roller, and four-roller micro-wire winding configurations are investigated. A multi-degree-of-freedom vibration model is established to analyze the natural frequencies of the micro-wire traveling system, and the tension variation characteristics in the machining region are further examined for different winding modes. Based on these analyses, a multi-wire micro-WEDM method and a corresponding three-roller winding mechanism are developed and validated through machining experiments. The effects of the number of wire electrodes on machining efficiency and accuracy are first evaluated, indicating that micro double-wire EDM provides an effective balance between efficiency and precision. Subsequently, the influences of open-circuit voltage, discharge capacitance, and feed rate on machining performance are systematically investigated to determine suitable processing parameters. Finally, the proposed method is successfully applied to the sustainable fabrication of a micro relay, achieving high machining efficiency and dimensional accuracy, thereby demonstrating its feasibility and practical potential. Micro-WEDM Reciprocating multi-wire Natural frequency Tension variation characteristics Three-roller winding mechanism Sustainable fabrication Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 09 Mar, 2026 Reviewers invited by journal 09 Mar, 2026 Editor assigned by journal 08 Mar, 2026 First submitted to journal 07 Mar, 2026 Editorial decision: Major Revisions Needed 27 Feb, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8884933","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":603179152,"identity":"6d32ee05-60c5-4498-87e1-197cb1744175","order_by":0,"name":"XIANG 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