Wire EDM Core Holding Using Localized Brass Deposition
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Solution Overview
Problem
In wire electric discharge machining, existing methods face challenges in securely holding cores during machining without over-bonding, leading to difficulties in striking off the core without damaging the workpiece base material, and require manual intervention for core cutoff, which is time-consuming and prone to errors.
Innovation Solution
A method that uses an automatic programming device to calculate the minimal necessary attachment points for brass deposits along the machining groove, optimizing the bonding strength and allowing for easy core removal by determining the center of gravity and strategically placing attachments to ensure stable fixation and easy detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If attachments are deposited all around the machining groove to securely hold the core, then the core fixation strength is improved, but it becomes difficult to strike off the core without damaging the workpiece base material
Solution Approach 1:
The patent applies local quality by depositing attachments only at specific locations (intersections of orthogonal straight lines passing through the center of gravity) rather than uniformly all around the machining groove. This localized attachment strategy provides sufficient core fixation strength while leaving other areas free for easy core removal without damaging the workpiece base material.
Solution Approach 2:
The patent uses partial action by depositing attachments only at critical strategic points rather than completely all around the groove. This partial deposition is sufficient to hold the core during machining but allows for clean separation when striking off the core, avoiding the need for excessive bonding that would cause damage.
2Productivity
If manual core cutoff is performed to remove the core after machining, then complete core removal is achieved, but operator burden increases and machining time is extended
Solution Approach 1:
The patent enables the core to be easily removed through self-service by designing the attachment pattern to allow simple striking off without manual intervention. The core can be removed by light taps that detach it from the workpiece base material, eliminating the need for operators to stay on the machine for cutoff machining and enabling unattended long-period machining.
Solution Approach 2:
The patent applies preliminary action by pre-calculating and pre-setting the attachment deposition locations during programming. The attachment/deposition region setting unit automatically determines optimal positions based on the machining shape, so that when machining is complete, the core can be easily removed without requiring additional manual cutoff operations.
3Strength
If the wire electrode contains brass to produce attachments, then core fixation is improved, but the complexity of controlling attachment deposition increases
Solution Approach 1:
The patent replaces complex mechanical control systems with an automated programming approach. The attachment/deposition region setting unit automatically calculates optimal attachment locations based on the machining shape and center of gravity, eliminating the need for manual intervention and reducing operational complexity while ensuring consistent core fixation strength.
Solution Approach 2:
The patent uses parameter changes by automatically adjusting the attachment deposition parameters (location, amount) based on the specific machining shape and requirements. The system changes the deposition parameters dynamically according to the calculated center of gravity and machining groove geometry, optimizing core fixation without requiring complex manual control.
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 approach reduces operator burden, minimizes risk of damage to the workpiece, enables unattended long-period machining, and eliminates the need for manual core cutoff, improving efficiency and reducing man-hours by ensuring secure core attachment and easy detachment.
Implementation Method 1
a wire electric discharge machine relatively moves a wire electrode containing brass and a workpiece in accordance with a machining program to machine the workpiece by electric discharge produced between the wire electrode and the workpiece
Implementation Method 2
attachments containing brass of the wire electrode are attached and deposited along the machining groove formed in the machining path
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3G
AI summary
In a wire electric discharge machine or an automatic programming device for a wire electric discharge machine, in which a core is held witch a workpiece base material by attaching brass contained in a wire electrode to the machining groove during machining, an attachment/deposition region where machining chips containing brass produced during machining are attached and deposited to the workpiece is set based on a machining shape obtained from a machining program and the machining chips containing brass produced during machining are attached and deposited according to the set attachment/deposition region.