Wire EDM Distortion Removal via Contact Detection
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Solution Overview
Problem
Conventional wire electric discharge machining methods for materials with large internal stress result in distortion, leading to increased machining time due to unknown distortion locations and amounts, especially in mass production of identical components.
Innovation Solution
A wire electric discharge machine equipped with an axial movement control, contact detection, non-contact position storage, machining path return control, and distortion amount calculation capabilities, allowing for identification of distortion-caused areas and efficient distortion removal machining by calculating and addressing the maximum distortion values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large machining margin is set to accommodate anticipated distortion, then machining accuracy is maintained, but machining time is significantly increased due to multiple rough machining operations
Solution Approach 1:
The system uses contact detection during wire electrode movement to obtain feedback information about distortion locations and amounts. The contact detection portion detects when the wire electrode contacts the workpiece, and the distortion amount calculation portion calculates distortion based on contact position data, enabling precise identification of distortion without requiring large safety margins
Solution Approach 2:
The patent replaces conventional mechanical measurement methods with electrical contact detection. By detecting electrical contact between the wire electrode and workpiece during controlled movement, the system identifies distortion locations and amounts without requiring multiple trial machinings or large machining margins
2Manufacturing precision
If conventional machining methods are used for materials with large internal stress, then distortion is addressed through multiple machining operations, but productivity decreases due to repeated rough machining
Solution Approach 1:
The wire electrode serves dual purposes: it performs both the machining function and the distortion detection function. During the return movement from machining end position to start position, the same wire electrode detects contact points that indicate distortion, eliminating the need for separate detection equipment or additional machining operations
Solution Approach 2:
The contact detection portion acts as an intermediary that translates mechanical contact between the wire electrode and workpiece into electrical signals for processing. This intermediary function enables the system to detect distortion locations and amounts by converting physical contact events into measurable data
Data Source
AI summary
When contact between a wire electrode and a workpiece is detected while, after wire electric discharge machining is ended, the wire electrode is moved (retraced) in the direction opposite to the machining direction along the machining path, the movement of the wire electrode is stopped. The wire electrode is moved in the offset direction from the contact position. When the wire electrode and the workpiece are brought into a non-contact state, the non-contact state is detected, and the movement of the wire electrode is stopped. The wire electrode is returned from the non-contact position to the machining path, and the wire electrode is retraced along the machining path in the state where the detection of contact between the wire electrode and the workpiece is neglected. Then, an amount of distortion of the workpiece is calculated from the contact position and the non-contact position.