Wire EDM Condition Transition for Stable Core Fixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rapid changes in machining conditions during the core fixing function in wire electrical discharge machining can lead to a decrease in discharge repulsive force, causing short-circuits and making it difficult to restart the machining process, as the wire electrode may become disconnected and stuck to the workpiece.
Innovation Solution
Implementing a medial machining condition that gradually transitions between the first and second machining conditions in a stepwise manner, reducing physical influences on the wire electrode, and incorporating dwell machining to maintain a discharge gap, thereby preventing unintentional disconnection and restart issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the core fixing function is activated to form fixing parts in the machined slot, then the cores are effectively fixed to the base material, but rapid change of machining condition causes decrease of discharge repulsive force leading to short-circuits and wire electrode disconnection
Solution Approach 1:
The patent applies dynamics by making the machining condition adjustable and transitionable between different states. The system dynamically switches between a first machining condition (with core fixing function active) and a second machining condition (with core fixing function inactive), allowing the discharge repulsive force to be maintained at appropriate levels during transitions, thereby preventing short-circuits and wire disconnection while ensuring reliable core fixing when needed.
2Productivity
If the core fixing function is used to machine numerous cores in one workpiece, then efficiency is improved and automatic operation is achieved, but rapid change of machining condition may cause the wire electrode to touch the workpiece and become stuck
Solution Approach 1:
The system dynamically adjusts machining conditions during the machining process, switching between different operational modes. When processing numerous cores, the system can activate the core fixing function to improve efficiency and automatic operation, then transition to a different machining condition after core fixing is complete, preventing the wire electrode from becoming stuck and maintaining continuous operation.
Solution Approach 2:
The patent applies preliminary action by preparing and setting the second machining condition in advance before the core fixing function is deactivated. This ensures that when the transition occurs after fixing numerous cores, the appropriate machining condition is already ready, preventing wire electrode disconnection and allowing seamless continuation of the high-productivity machining process.
3Speed
If the machining condition is rapidly changed during core fixing function switching, then the transition between processing modes is quick, but instantaneous discharge and short-circuit occur increasing the risk of wire electrode disconnection
Solution Approach 1:
The system uses dynamic control to manage the transition between machining conditions. Rather than abrupt switching, the system dynamically adjusts parameters during the transition phase, maintaining appropriate discharge repulsive force levels to prevent instantaneous discharge and short-circuits, thereby ensuring wire electrode stability during condition changes.
Solution Approach 2:
The patent applies beforehand cushioning by preparing the second machining condition in advance and ensuring a smooth transition process. This cushioning approach prevents instantaneous discharge and short-circuits during the transition from core fixing mode to normal machining mode, protecting the wire electrode from disconnection while maintaining efficient operation.
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 effectively prevents unintentional unrestorable events and wire electrode disconnections during core fixing function transitions, ensuring continuous operation by maintaining a stable discharge gap and reducing the risk of short-circuits.
Implementation Method 1
performing electrical discharge machining on a workpiece by electric discharge generated between a wire electrode and a workpiece
Implementation Method 2
uses a phenomenon that components of the wire electrode adhere to the workpiece during electric discharge to fix the formed core to the base material of the workpiece
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A machining condition setter (42) in a wire electrical discharge machine (10), sets up: as machining conditions, a first machining condition for enabling the core fixing function in a first section (IN1) on the upstream side; a second machining condition for enabling formation of a slot (58, 59) in the workpiece (W) in a second section (IN2) on the downstream side; and a medial machining condition that is different from the first machining condition and the second machining condition in a medial section (INm) located between the first section (IN1) and the second section (IN2).