In the Wire Electrical Discharge Machining (WEDM) process, establishing a reliable benchmark is crucial. As WEDM is a precision machining technique, improper reference correction during processing can lead to poor workpiece quality and affect its functional performance. For small-shaped workpieces with limited processing areas but a large quantity (as shown in Fig. 1), multiple clamping operations are often required due to the machine tool's thickness limitations. This necessitates recalibrating the baseline before each operation, significantly increasing the workload.

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Figure 1

The setup for the positioning reference block is straightforward, consisting of electromagnets, reference blocks, and machine tool fixtures (as shown in Fig. 2). Since the workpiece requires an open area for processing, only a limited number can be placed on the clamping plate at once. At this point, the workpiece’s center of gravity becomes unstable, risking it from flipping over. To prevent this, an electromagnet is used to secure the workpiece in place. During the initial calibration, the X and Y coordinates of the table are recorded. In subsequent operations, the workpieces just need to be laid flat and aligned with the A and B surfaces. The wire then passes through the pre-drilled hole’s center, and the previously recorded X and Y values are used for accurate processing. The A and B surfaces must remain perpendicular and meet specific surface roughness standards. The reference block should not exceed the height of the electromagnet to ensure proper alignment. This tool is simple to manufacture, easy to use, time-efficient, and highly adaptable. It is also easy to implement and apply in industrial settings, making it an effective solution for improving efficiency and accuracy in WEDM processes.

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Figure 2
1. Machine tool fixture 2. Reference block 3. Electromagnet

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October 11, 2025