Aiming at the problems such as insufficient ability to detect discharge state and hysteresis of output of existing wire-cut pulse power supply, a self-adjusting pulse power supply based on FPGA is developed. The power supply can accurately identify the discharge state of each processing pulse by high-speed A/D sampling. By adjusting the pulse output frequency in real time according to different discharge states, the harmful discharge state can be suppressed and the effective discharge pulse ratio can be improved. The experimental results show that the machining efficiency of the Connecting Rod Cutting machine is improved by using the self-tuning pulse power supply, compared with that by using the constant frequency pulse power supply. The pulse power supply promotes the development of the reciprocating wire cutting machine to high efficiency, energy saving and automation.

Multi-channel wire electrical discharge machining (MC-WEDM) is an advanced and high-efficiency machining technology, but its material erosion mechanism remains unclear. In this study, dual-channel wire electrical discharge machining was utilized as a case study to investigate the impact of the plunging current on both the plasma characteristics and material erosion under complex discharge conditions. Force analysis was conducted on the charged particles in the plasma, revealing that the plunging current can influence the trajectory of the plasma by modifying the self-magnetic field. The particle tracking method was employed to simulate the motion of electrons, revealing that in MC-WEDM, electrons exhibited a larger and more uniform distribution. The evolution of the plasma within a single-pulse discharge was observed using high-speed photography technology, and the discharge signals collected from different channels were analyzed. It was observed that the plasma in MC-WEDM experienced more intense back-and-forth sweeping on the workpiece surface, facilitating the ejection of molten metal from the molten pool. The oscillating plasma exhibits a larger processing area and a more uniform distribution of energy, resulting in the formation of larger and shallower discharge craters. Furthermore, the influence of the amplitude and time point of the plunging current on the volume and area of the discharge craters was summarized. Finally, MC-WEDM significantly reduced the occurrence of holes and micro-cracks and exhibited a thinner recast layer in the continuous discharge experiment.