Horizontal Wire EDM Layout for Large Build Plate Separation
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Solution Overview
Problem
Existing wire electrical discharge machining tools are inadequate for quickly and accurately separating large and heavy metal pieces from build plates in additive manufacturing, due to limitations in size and weight capacity, and require expensive and large submersion tanks.
Innovation Solution
A horizontal submerged fast wire electrical discharge machining tool is designed with the wire placed above the build plate, requiring only the wire to be submerged, allowing for larger and heavier pieces to be machined by reducing the size of the submersion tank and minimizing motorized and moving parts, while maintaining accuracy and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If existing vertical wire electrical discharge machining tools are used, then the machining process can be performed, but the size and weight of pieces that can be machined are limited
Solution Approach 1:
The patent inverts the traditional vertical wire EDM configuration to a horizontal orientation. The wire travels horizontally through the workpiece rather than vertically, allowing large and heavy additively manufactured pieces to be machined without the size and weight limitations of vertical configurations. This inversion enables the workpiece to remain in its natural horizontal position on the build plate throughout the machining process.
Solution Approach 2:
The patent transitions from a vertical (one-dimensional height-oriented) machining approach to a horizontal (one-dimensional length-oriented) approach. This dimensional change allows the machining system to accommodate workpieces with larger horizontal dimensions and greater weight, as the wire travels along the horizontal axis rather than vertically through the workpiece.
2Volume of moving object
If existing horizontal wire electrical discharge machining tools are used, then larger pieces can be machined, but expensive and large submersion tanks are required
Solution Approach 1:
The patent extracts the submersion requirement from the entire workpiece and build plate assembly, applying it only to the critical machining zone where the wire contacts the workpiece. A localized submersion tank or dielectric reservoir is positioned only at the cutting area, rather than submerging the entire large workpiece and build plate, thereby dramatically reducing the volume of the stationary submersion tank required.
Solution Approach 2:
The patent applies submersion locally only to the machining zone rather than globally to the entire workpiece and build plate. The dielectric fluid is contained in a localized reservoir at the cutting area, providing necessary cooling and flushing only where electrical discharges occur, while the rest of the large workpiece remains above the fluid level.
3Productivity
If existing wire electrical discharge machining tools are used, then machining can be performed, but the separation speed and accuracy are insufficient
Solution Approach 1:
The patent employs a continuous wire that travels horizontally through the workpiece in an unbroken path, enabling continuous machining action without the need to stop and reposition. The wire moves continuously through the dielectric fluid and along the build plate, maintaining constant cutting action that improves both speed and consistency of the separation process.
Solution Approach 2:
The patent replaces traditional mechanical cutting methods with electrical discharge machining, where electrical energy erodes the material rather than mechanical force. This substitution enables precise separation of large metal pieces from build plates without the vibrations, tool wear, and positioning errors associated with mechanical machining, thereby improving both accuracy and speed.
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
This configuration enables the machining of pieces that are double in size and weight compared to existing systems, with easier maintenance and no sacrifice in accuracy or speed, allowing for efficient separation of large 3D printed metal pieces from build plates.
Implementation Method 1
Wire electrical discharge machining is a machining process which can quickly and accurately cut any electrically conductive metal using electrical discharges
Data Source
AI summary
A system and method provide for a horizontal wire electrical discharge machining apparatus, including a gantry frame positioned above a worktable to support a workpiece, a reciprocating cutting wire spooled to and from a single drum spool through wire guides and an automatic wire tensioner, wherein during operation the reciprocating cutting wire is pulsed with electric current to erode a surface of the workpiece and the worktable supporting a build plate and the workpiece. The machining apparatus also includes a submersion tank containing deionized water to submerge a face of the build plate and a series of pulleys, the wire guides and the automatic wire tensioner arranged to position the reciprocating cutting wire parallel to the face of the build plate and below a surface of the deionized water in the submersion tank.