Wire EDM Continuous Corner Speed Control
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Solution Overview
Problem
The precision of corner shapes in wire electrical discharge machining is degraded when machining continuous corners, as existing techniques fail to accurately calculate the machining speed reference for overlapping pre-corner and post-corner sections.
Innovation Solution
A wire electrical discharge machining apparatus that includes devices for calculating representative speeds, pre-corner and post-corner section lengths, corner speed coefficients, and interpolation of these coefficients to determine appropriate machining speed references, enabling precise control of machining speeds during the machining of continuous corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the machining speed is controlled based on corner speed coefficients calculated for single corners, then the shape precision of single corner parts is improved, but the shape precision of continuous corner parts degrades due to inability to calculate appropriate speed references for overlapping sections
Solution Approach 1:
The patent segments the corner machining process into distinct sections: pre-corner sections where machining volume changes transitionally before corner entrance, middle corner sections where machining volume is constant, and post-corner sections where machining volume changes transitionally after corner exit. By calculating corner speed coefficients for each segment type and detecting continuous corner conditions, the system applies appropriate speed control strategies to each segment, resolving the contradiction between single-corner precision and continuous corner adaptability.
2Manufacturing precision
If the machining volume per unit time is uniformly controlled for straight and corner parts, then the corner shape precision is improved, but the machining speed reference cannot be accurately calculated for overlapping continuous corner sections
Solution Approach 1:
The patent implements a feedback mechanism where the continuous corner detection device monitors the machining conditions and determines whether continuous corner sections are present. Based on this detection feedback, the speed reference calculation device selects appropriate calculation methods: using interpolated corner speed coefficients for non-overlapping sections and alternative reference methods for overlapping sections. This feedback loop ensures accurate machining speed reference calculation across all corner types, maintaining both precision and adaptability.
3Productivity
If the pre-corner and post-corner sections are made very short to enable quick transition, then the machining efficiency is improved, but the shape precision degrades when these sections overlap in continuous corners
Solution Approach 1:
The patent applies dynamic speed control where the machining speed is continuously adjusted based on the detected corner section type and continuous corner conditions. The drive control device dynamically modifies the wire electrode speed according to calculated speed references, allowing short pre-corner and post-corner sections for efficiency while maintaining precision through real-time speed adaptation in overlapping continuous corner regions.
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 allows for improved shape precision of continuous corner parts by accurately calculating and interpolating machining speed references, even when corner sections overlap, thereby enhancing the machining precision.
Implementation Method 1
a wire electrical discharge machining process
Implementation Method 2
applying a pulse voltage between a wire electrode and a workpiece
Implementation Method 3
applying a pulse voltage between a wire electrode and a workpiece while relatively moving the wire electrode and the workpiece
Data Source
AI summary
A wire electrical discharge machining apparatus capable of improving the shape precision of a continuous corner part includes a corner speed coefficient calculation device calculating a machining speed ratio between a middle corner section and a straight part from a machining volume ratio between the straight part and the middle corner section in which machining volume becomes a constant value. A corner speed coefficient interpolation device interpolates a speed coefficient calculated by the corner speed coefficient calculation device in a pre-corner section and a post-corner section. A speed reference calculation device calculates a machining speed reference based on a representative speed and the corner speed coefficient, and a drive control device controls a drive device. A continuous corner detection device determines whether continuous corner sections overlap each other when the length of the straight part connecting two corner parts is shorter than the length of the pre-corner section.