Wire Cut EDM Controller for Arc Corner Accuracy
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Solution Overview
Problem
Machining accuracy is reduced in corner portions of workpieces during wire cut electric discharge machining due to wire electrode deflection and variation in machining energy and coolant flow, especially at small circular arc radii, with existing techniques being complex and impractical for effective control.
Innovation Solution
A controller for wire cut electric discharge machines that adjusts discharge quiescent time inversely with the circular arc radius and controls coolant volume based on the ratio of discharge pulses, optimizing machining energy, speed, and electrode straightness to improve accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high machining speed is used in rough machining, then productivity is improved, but wire electrode deflection increases and machining accuracy deteriorates
Solution Approach 1:
The patent applies dynamics by making the discharge quiescent time variable rather than constant. The control device dynamically adjusts the discharge quiescent time based on the circular arc radius of the corner portion being machined, allowing the machining parameters to adapt to different geometric conditions and maintain both speed and accuracy
Solution Approach 2:
The patent changes the parameter of discharge quiescent time based on the circular arc radius. By establishing a relationship between the circular arc radius and the discharge quiescent time, the system optimizes machining parameters for different corner geometries, reducing wire deflection while maintaining productivity
2Productivity
If intense machining energy is applied in rough machining, then productivity is improved, but wire electrode vibration increases and machining accuracy deteriorates
Solution Approach 1:
The system dynamically adjusts discharge quiescent time based on real-time machining conditions and geometric parameters. By making the quiescent time variable rather than fixed, the system can modulate machining energy intensity to prevent excessive wire vibration while maintaining high productivity
Solution Approach 2:
The control device uses feedback from the machining conditions (circular arc radius, machining speed) to adjust the discharge quiescent time. This feedback mechanism allows the system to respond to changing conditions and maintain optimal energy levels that prevent wire deflection
3Adaptability or versatility
If small circular arc radius is machined, then adaptability is improved, but wire electrode deflection increases and machining accuracy deteriorates
Solution Approach 1:
The patent establishes a specific relationship between the circular arc radius parameter and the discharge quiescent time parameter. By adjusting the discharge quiescent time according to the circular arc radius, the system maintains machining accuracy across different corner geometries, from small to large radii
Solution Approach 2:
The system dynamically adapts the discharge quiescent time to match the specific geometric requirements of each corner portion. This dynamic adjustment allows the system to handle a wide range of circular arc radii while maintaining consistent machining quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The controller significantly enhances machining accuracy by reducing wire electrode deflection and maintaining optimal machining conditions, improving the straightness of the wire electrode and machining precision at circular arc corners.
Implementation Method 1
a wire electrode moves relatively to a workpiece along a programmed machining locus while applying a pulse current to a gap between the wire electrode and the workpiece
Implementation Method 2
jet flow of machining fluid (coolant)
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
In a wire cut electric discharge machine, a discharge quiescent time OFFr is controlled to be longer than a reference discharge quiescent time OFFs when machining a circular arc corner portion having a circular arc radius R that is smaller than a reference circular arc radius R0. For example, OFFr = OFFs×R0/R is satisfied. By controlling the discharge quiescent time in this manner, the machining accuracy of machining a circular arc corner of a workpiece can be improved.