Horizontal-Axis Wire EDM Layout for Variable-Diameter Disc Cutting
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Solution Overview
Problem
Conventional wire electrical discharge machines (WEDM) are not optimized for machining turbine discs with varying diameters, requiring large machine sizes and complex setups, limiting their versatility and efficiency in cutting circular parts with different dimensions and profiles.
Innovation Solution
A compact WEDM machine design featuring a horizontally oriented first rotary axis unit, orthogonal linear axis units, and a movable machine table with wire guiding heads, allowing for adaptable support and machining of circular parts with different sizes and shapes without increasing machine size, enabling efficient cutting of contours on the periphery of parts like turbine discs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional WEDM machines are designed to accommodate turbine discs with varying diameters, then the machine size must be increased, but this increases device complexity and reduces versatility
Solution Approach 1:
The patent implements a dynamically adjustable positioning system where the distance between the rotary axis and the wire electrode can be varied. The machine table can be moved along the X-axis to change the working distance, allowing the same machine to accommodate turbine discs of different diameters without requiring physical reconfiguration or enlargement of the machine structure
Solution Approach 2:
The patent changes the working parameters of the machine by allowing adjustment of the table position and wire electrode distance. By varying these parameters, the machine can adapt to different disc diameters while maintaining the same physical machine size, thus resolving the contradiction between adaptability and device complexity
2Productivity
If the machine table is positioned close to the wire electrode for efficient machining, then machining efficiency is improved, but the machine cannot accommodate larger diameter parts
Solution Approach 1:
The machine table is designed with dynamic positioning capability along the X-axis, allowing it to be moved closer to the wire electrode for efficient machining of smaller parts, or positioned farther away to accommodate larger diameter turbine discs. This dynamic adjustment resolves the contradiction between maintaining close positioning for efficiency and accommodating larger parts
3Manufacturing precision
If dedicated tools are used for machining specific profiles, then machining accuracy is improved, but the process requires tool adaptation for profile modifications
Solution Approach 1:
The patent employs a universal wire electrode system that can cut any desired contour by reprogramming the machining path rather than requiring dedicated tools for each profile. The wire electrode serves multiple functions by adapting to different cutting paths and parameters, achieving both high precision and flexibility for profile modifications
Solution Approach 2:
The patent replaces the mechanical tool adaptation system with a programmable control system. Instead of physically adapting tools for different profiles, the machine uses software-controlled wire electrode positioning and movement, substituting mechanical complexity with computational flexibility while maintaining machining precision
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 machine enables efficient machining of circular parts with varying dimensions and profiles, reducing machine size and complexity, enhancing versatility and accuracy, and allowing for easy adaptation to different parts without the need for extensive reconfiguration, while maintaining high surface quality and minimizing handling risks.
Implementation Method 1
The process is conducted by applying a pulsed voltage to the gap between the wire electrode and the part to provoke discharges between the work piece and the wire. The material of the part is removed by the discharges occurred between the gap.
Data Source
Figure 1a~2b
Figure 3~4
Figure 5a~5c
AI summary
The present invention is related to a wire electrical cutting machine for machining a circular part by a wire electrode. The machine comprises a machine base (10); a column (20) mounted on the machine base; a first rotary axis unit for rotating the part around a first rotary axis (C), wherein the first rotary axis is mounted on the column and the first rotary axis is arranged horizontally; a machine table (30) bearing a wire traveling circuit (40), which includes a first wire guiding head (41) and a second wire guiding head (42) and the wire electrode (45) traveling between the first wire guiding head and the second wire guiding head, in particular in one direction; and a first linear axis unit (12) for linear movement of the machine table in a first linear axis direction and a second linear axis unit (11)for linear movement of the machine table in a second linear axis direction, wherein the first linear axis unit is mounted on the machine base and the second linear axis unit is mounted on the first linear axis unit and the machine table is mounted on the second linear axis unit, wherein the first- and the second linear axes are arranged orthogonally with respect to each other and orthogonally with respect to the first rotary axis; wherein the wire electrode is positioned below the first rotary axis to machine the part.