EDM Electrode and Adhesive Jig for Full-Periphery Precision Machining
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Solution Overview
Problem
Existing electrical discharge machining technologies suffer from poor surface roughness and surface cracks, and are limited by the need to reposition the jig to cut areas obscured by clamping, leading to incomplete machining.
Innovation Solution
An electrical discharge machining apparatus with a carrier and jig system that employs discharge electrodes with non-uniform electric field distribution, adhesive layers, and conductive gain layers to improve machining precision and flexibility, allowing for simultaneous cutting and polishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a jig is used to clamp the periphery of the ingot radially to prevent rolling or displacement, then the stability of the ingot is improved, but the machining area is limited to only the exposed outer side, leaving overlapping areas between the jig and ingot that cannot be machined
Solution Approach 1:
The patent employs a rotary table that rotates the carrier plate and clamped ingot during the electrical discharge machining process. This dynamic rotation allows the discharge electrode to access and machine all peripheral surfaces of the ingot, including areas that would otherwise be obscured by the jig's clamping structure. The rotary mechanism transforms a static limitation into a dynamic solution, enabling complete 360-degree machining while the ingot remains securely clamped.
2Manufacturing precision
If the machine is stopped to readjust the position to enable cutting again, then complete machining of all areas can be attempted, but productivity is reduced due to repeated stopping and repositioning
Solution Approach 1:
The patent achieves continuous machining by combining the rotary table with a discharge electrode configured for circular or spiral motion. As the rotary table continuously rotates the ingot, the discharge electrode follows a corresponding circular or spiral path, maintaining uninterrupted electrical discharge machining throughout the entire periphery. This eliminates the need to stop and reposition the machine, as the system is designed to machine all surfaces in a single continuous operation.
3Device complexity
If conventional electrical discharge machining is used with uniform electric field distribution, then the machining process is simple, but the roughness of the cut surface is poor and surface cracks occur
Solution Approach 1:
The patent employs a discharge electrode with non-uniform electric field distribution, where the electric field intensity varies at different locations along the electrode. This non-uniform distribution creates zones of different discharge intensity, allowing for controlled material removal that produces smoother surfaces with fewer cracks. The varying electric field strength enables finer control over the machining quality without requiring complex additional equipment.
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 apparatus reduces surface roughness and cracks by concentrating electric fields in the machining direction, avoids jitter and burrs, and enables flexible machining without repositioning, enhancing overall machining efficiency.
Implementation Method 1
electrical discharge machining (EDM) unit applies a discharge energy to a machining target area of the to-be-machined object through at least one discharge electrode
Implementation Method 2
applies a discharge energy to the machining target area of the to-be-machined object through at least one discharge electrode with a non-uniform electric field distribution, thereby machining the to-be-machined object along the machining target area
Data Source
AI summary
An electrical discharge machining apparatus comprises a carrier and an electrical discharge machining (EDM) unit. The carrier is provided with a jig comprising a carrier plate for carrying a to-be-machined object, and the to-be-machined object is defined with a machining target area. The electrical discharge machining (EDM) unit applies a discharge energy to the machining target area through a discharge electrode with a non-uniform electric field distribution, so that the electric field is concentrated on a traveling direction. The carrier plate has an adhesive layer capable of adhering and fixing the to-be-machined object, capable of avoiding jitter of the to-be-machined object during an electrical discharge machining procedure, and capable of avoiding burrs before an end of the electrical discharge machining procedure, and making the machining target area to be located above the carrier plate to be capable of preventing the jig from hindering the electrical discharge machining procedure.