EDM Rotary Fixture Layout for Large-Part Angled Wire Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional EDM machines are limited by physical constraints such as maximum angle and clearance height, restricting the size and type of components that can be machined, particularly for aircraft components like annular turbine parts that require larger clearance and greater angled cuts.
Innovation Solution
A rotary table fixture for EDM machines that includes a mounting portion with radial slots and sections with fastener features, allowing for increased clearance and angle of the machining wire beyond the typical limitations, enabling the machining of larger components by extending the mounting surface below the fixed table and incorporating features like key slots and clocking pins for precise orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional EDM machine is used with a fixed table, then the machine structure is simple and easy to operate, but the clearance height is limited and the maximum cutting angle is restricted
Solution Approach 1:
The fixed table is segmented into a rotary table and a fixture assembly. The rotary table can rotate to different positions, and the fixture can be adjusted independently, allowing the machining wire to achieve greater clearance heights and cutting angles without complicating the overall machine structure.
Solution Approach 2:
The fixed table is replaced with a rotary table that can dynamically adjust its position and orientation. This dynamic capability allows the system to achieve variable clearance heights and cutting angles, transforming a static limitation into a flexible solution.
2Adaptability or versatility
If the guide wire is angled relative to the normal line for specific component configurations, then the machining capability for certain parts is improved, but the maximum angle is limited by physical constraints
Solution Approach 1:
The rotary table provides dynamic angular adjustment capability, allowing the guide wire to be positioned at various angles relative to the component. This enables the system to adapt to different component configurations and machining requirements beyond the fixed angle limitations of conventional EDM machines.
Solution Approach 2:
The rotary table introduces an additional rotational dimension to the system. By rotating the table, the guide wire can approach the component from different angular perspectives, effectively adding a dimensional degree of freedom that overcomes the single-angle limitation of conventional fixed-table EDM machines.
3Length of moving object
If the mounting surface is extended below the fixed table, then the clearance for large components is increased, but the fixture structure becomes more complex
Solution Approach 1:
The fixture is divided into multiple adjustable segments or components that can be independently positioned. This segmentation allows the mounting surface to be extended below the table in a controlled manner, providing increased clearance while maintaining manageable structural complexity through modular design.
4Manufacturing precision
If radial slots and fastener features are incorporated in the mounting portion, then the positioning precision and clamping capability are improved, but the manufacturing complexity increases
Solution Approach 1:
The mounting portion is divided into radial slots that create discrete positioning zones. These slots, combined with fastener features, provide precise positioning capability while allowing the fixture to be manufactured from standard materials using conventional machining processes, balancing precision with manufacturability.
Data Source
AI summary
An EDM machine includes a machine head, a wire guide, a machining wire extending from the wire guide to the machine head, a rotary table mounted to a first surface and a fixed table mounted to the rotary table, and a fixture mounted to the fixed table. The fixture includes a mounting portion substantially circumscribing the fixture. The mounting portion further includes a mounting surface. The mounting surface is closer to a first surface than an upper surface of the fixed table.