Conductive Part Support Plate Referencing for EDM Cutoff
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Solution Overview
Problem
Current additive manufacturing techniques, such as Selective Laser Melting, do not allow for precise monitoring of part references, making subsequent cutting and rework operations time-consuming and expensive due to the need for mechanical detachment from the support plate.
Innovation Solution
A method using a first additive manufacturing machine to create a part with a support bridge and a reference element on the support plate, allowing precise positioning for electroerosion cutting using a second machine, enabling complex trajectories and eliminating the need for subsequent rework.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to manufacture parts on a support plate, then manufacturing flexibility and complex geometries are improved, but precise positioning and tracking of part references deteriorate
Solution Approach 1:
Reference elements are manufactured simultaneously with the part on the support plate during the additive manufacturing process, establishing precise positional relationships before the part is detached and moved to the cutting machine. This preliminary establishment of references eliminates the need for subsequent positioning operations.
Solution Approach 2:
The support plate serves dual functions: it supports the part during additive manufacturing and provides the reference system for subsequent cutting operations. The support plate essentially references itself by having the reference elements manufactured on it during the same process, eliminating the need for external referencing systems.
2Productivity
If cutting is performed close to the support plate without precise reference tracking, then manufacturing time is reduced, but manufacturing precision and subsequent rework requirements worsen
Solution Approach 1:
The reference elements are manufactured in advance on the support plate with precise positional relationships to the part. This preliminary action enables the cutting machine to immediately locate and cut the part with high precision without requiring subsequent positioning or rework operations.
3Manufacturing precision
If multiple separate operations (additive manufacturing, positioning, cutting, rework) are used, then manufacturing precision is maintained, but device complexity and manufacturing time increase
Solution Approach 1:
The support plate is used as a common platform for both additive manufacturing and electroerosion cutting operations. By manufacturing reference elements on the support plate during additive manufacturing, the system merges two separate processes into a coordinated workflow, reducing the need for complex positioning and rework operations between machines.
Solution Approach 2:
The support plate serves multiple functions: it acts as the build platform for additive manufacturing, provides the reference system for positioning, and serves as the base for the cutting operation. This multi-functionality eliminates the need for separate positioning and referencing systems.
4Manufacturing precision
If traditional cutting and rework operations are used, then manufacturing precision is achieved, but loss of time and manufacturing costs increase
Solution Approach 1:
Reference elements are manufactured simultaneously with the part during the additive manufacturing process, establishing precise positional relationships before the part is detached. This preliminary establishment of references enables direct cutting to finished dimensions without subsequent positioning or rework operations, eliminating time losses.
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
Facilitates precise and efficient cutting of parts to finished dimensions, reducing rework operations and mechanical stress, while allowing for the production of complex geometries with reduced manufacturing time and costs.
Implementation Method 1
using a wire from said second machine to cut said at least one part by electroerosion by passing it between said at least one part and said support plate
Implementation Method 2
fusing powder using a high-energy beam such as a laser beam (SLM technology, acronym for Selective Laser Melting)
Data Source
Figure 1
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Figure 6~8
AI summary
Method for manufacturing at least one part (8) of electroconductive material by additive manufacturing on a bed of powder, characterised in that it comprises the steps of manufacturing the part on a support plate of a first additive manufacturing machine, layer by layer, said part being bounded by an external contour surface portion which is opposite and spaced apart from said support plate, and which is connected to said support plate by at least one bridge of support material of the part, providing a reference element (51) on the support plate in a predetermined position, mounting said support plate on a second machine (60) for cutting said at least one part, and using a wire (62-66) of said second machine for cutting by electrical discharge machining said at least one part by passing it between said at least one part and said support plate, along and at the level of said surface portion.