Wire EDM Feed Rate Control for Accurate Corner Machining
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Solution Overview
Problem
Conventional wire electrical discharge machining methods struggle to maintain precise control over the gap distance between the wire electrode and the workpiece, especially when machining corner-shaped curved paths, leading to reduced shape accuracy due to variations in geometry.
Innovation Solution
A wire electrical discharge machine and method that incorporates a voltage detector, facing area calculation unit, and axis feed rate determination unit to adjust the axis feed rate based on detected gap voltage and facing area, ensuring the wire electrode moves relative to the workpiece at an optimized rate to maintain a constant gap distance, regardless of the workpiece geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the axis feed rate is controlled to maintain a constant gap voltage during machining, then the gap distance can be kept constant for straight path machining, but the machining accuracy degrades when machining corner-shaped curved paths due to varying proportional coefficients between gap voltage and gap distance
Solution Approach 1:
The patent applies dynamics by making the axis feed rate adjustable and adaptive based on the machining path geometry. The control unit dynamically modifies the axis feed rate according to the curvature radius of the machining path, transitioning from a static constant feed rate to a dynamic variable feed rate that adapts to different geometric conditions, thereby maintaining constant gap distance across various path types
Solution Approach 2:
The patent changes the parameter of axis feed rate based on the curvature radius of the machining path. By establishing a relationship between curvature radius and axis feed rate, the system adjusts the feed rate parameter to compensate for geometric variations, ensuring that the proportional relationship between gap voltage and gap distance remains valid across different path geometries
2Manufacturing precision
If the pause time of electrical discharging is changed to control material removal amount, then machining accuracy can be improved for corner-shaped curved paths, but the control complexity increases and cannot fully maintain constant gap distance
Solution Approach 1:
The patent changes the parameter of axis feed rate based on the curvature radius of the machining path. By establishing a relationship between curvature radius and axis feed rate, the system adjusts the feed rate parameter to compensate for geometric variations, ensuring that the proportional relationship between gap voltage and gap distance remains valid across different path geometries
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 enables high-precision machining by compensating the target voltage and adjusting the axis feed rate according to changes in the facing area, effectively maintaining a constant gap distance and improving machining accuracy along various workpiece geometries.
Implementation Method 1
a voltage detector configured to detect a gap voltage across the electrode gap
Implementation Method 2
performing electrical discharge machining on a workpiece by applying voltage across an electrode gap formed between a wire electrode and the workpiece to thereby generate electrical discharge
Data Source
AI summary
A wire electrical discharge machine performs electrical discharge machining on a workpiece by applying voltage across an electrode gap formed between a wire electrode and the workpiece to thereby generate electrical discharge while moving the wire electrode relative to the workpiece along a path specified by a machining program. The wire electrical discharge machine includes: a voltage detector for detecting a gap voltage across the gap; a facing area calculation unit for calculating, as a facing area, the area of a surface of the workpiece contained within a predetermined distance from the center axis of the wire electrode; an axis feed rate determination unit for determining an axis feed rate based on the gap voltage value detected by the voltage detector, and the facing area; and a movement control unit for performing control so that the wire electrode moves relative to the workpiece at the axis feed rate.