Wire EDM Approach Path Generation for Stable Fluid Pressure
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Solution Overview
Problem
Existing wire electrical discharge machining systems face issues with wire electrode breakage due to insufficient cooling caused by reduced pressure of the working fluid in the machining gap, especially when the machining start position has a large through hole, leading to decreased machining speed.
Innovation Solution
A program generation device and method that generates an approach path for wire electrical discharge machining, where the direction changes at designated via-points to ensure the working fluid pressure is maintained at a high level by directing the fluid towards the nearest machined path section, preventing wire electrode breakage and maintaining machining speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the machining start position has a large through hole, then the wire electrode can be easily threaded, but the working fluid pressure decreases causing wire electrode breakage
Solution Approach 1:
The approach path is divided into multiple line segments connecting via-points, allowing the path to be segmented to avoid direct straight-line paths that cause pressure loss, while still enabling wire electrode threading through the large through hole
Solution Approach 2:
The approach path is extended into a multi-dimensional path with via-points that redirect the working fluid flow, transforming the simple radial path into a complex multi-segment path that maintains pressure while achieving the same threading function
2Productivity
If the approach path is a straight line, then the path is simple and short, but the working fluid pressure is insufficient causing wire electrode breakage
Solution Approach 1:
The approach path is made dynamic by introducing via-points that allow the path to adapt its geometry, transforming from a static straight line to a dynamic multi-segment path that can maintain working fluid pressure while still being efficient
Solution Approach 2:
Via-points are introduced as intermediary elements that redirect the working fluid flow and maintain pressure, acting as mediators between the machining start position and the connection element on the machining path
3Length of moving object
If the approach path passes close to the machining start position, then the path length is reduced, but the working fluid pressure decreases causing wire electrode breakage
Solution Approach 1:
The approach path utilizes multi-dimensional space by introducing via-points at different positions, creating a path that may be longer in Euclidean distance but maintains working fluid pressure through strategic routing, preventing wire electrode breakage
Data Source
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Figure 3A~3C
AI summary
An aspect of the present disclosure is a program generation device that generates a machining program, the program generation device comprising: an acquisition unit that acquires a machining start point and a machining path; a determination unit that determines a connection element to which an approach path is to be connected and a waypoint through which the approach path is to pass; an approach path generation unit that generates the approach path going from the machining start point, through the waypoint, to the connection element; and a machining program generation unit that generates the machining program, wherein the approach path generation unit generates the approach path such that the direction of the approach path changes at the waypoint.