Auxiliary Guide for Wire Electrode Threading in EDM
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Solution Overview
Problem
Wire EDM machines face challenges in threading wire electrodes due to the lack of auxiliary guide means between the upper and lower wire guide heads, especially when dealing with varying wire thicknesses, dielectrics, and small starting holes, which limits the effectiveness of existing threading devices.
Innovation Solution
A mechanical auxiliary guide, designed as an open tube with a longitudinally introduced C-shaped or V-shaped guide channel, is used to guide the wire electrode from the upper wire guide head to the lower wire guide head, providing precise guidance and extending the wire run system, allowing for threading into small starting holes and reducing the need for complex constructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressure chamber threading device is used with the upper wire guide head, then threading effectiveness is improved, but it can only be used under ideal conditions and fails when threading on the periphery or in remote areas
Solution Approach 1:
An auxiliary guide is introduced as an intermediary element between the wire electrode and the workpiece. This auxiliary guide extends the wire run system and provides a mechanical guidance path that works independently of the pressure chamber system, enabling threading in locations where the pressure chamber method fails, such as periphery and remote areas.
Solution Approach 2:
The threading function is segmented into two independent systems: the original pressure chamber system for ideal conditions, and the new auxiliary guide system for difficult locations. This segmentation allows each system to be optimized for its specific use case without compromising the other, improving overall adaptability.
2Reliability
If a closed tube guide is used to guide the wire to the workpiece, then threading safety is improved, but the wire guide has to be opened or moved requiring special construction
Solution Approach 1:
The auxiliary guide acts as a temporary intermediary during the threading process only. It is not permanently integrated into the wire guide structure, avoiding the need to open or move the wire guide. The auxiliary guide can be positioned and removed as needed, maintaining the integrity and simplicity of the original wire guide construction.
Solution Approach 2:
The auxiliary guide is designed to be dynamically positionable rather than fixed. It can be moved into position for threading operations and then removed or repositioned, providing the safety of enclosed guidance only when needed without permanently complicating the wire guide structure.
3Manufacturing precision
If the wire is stretched and severed before threading to create a tapered tip, then threading precision is improved, but additional processing steps are required
Solution Approach 1:
The auxiliary guide provides preliminary mechanical guidance during the threading process itself, eliminating the need for preliminary wire tip preparation through stretching and severing. The guide channel pre-positions and directs the wire tip into the workpiece, achieving precision without additional processing steps.
Data Source
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AI summary
The application relates to a threading device 30 for wire EDM machines for threading wire electrodes 2 from an upper wire guide head 10 of the wire EDM machine through the working area of the wire EDM machine into a lower wire guide head 20 of the wire EDM machine. The invention is characterized in that the threading device 30 has an auxiliary guide 31 that can be positioned between the upper and the lower wire guide heads 10, 20, which is equipped with a groove-shaped, open guide channel 32 for the actual guiding of the wire electrode 2 to be threaded – or rather, of its wire electrode tip 3.