Wire EDM Keyway Program Device Preventing Opening Narrowing
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Solution Overview
Problem
Conventional keyway milling using wire electric discharge machines is inefficient due to low productivity and accuracy issues, particularly when operators unfamiliar with general-purpose machines attempt to create machining programs, leading to narrowed keyway openings and reduced shape accuracy.
Innovation Solution
A machining program creating device for wire electric discharge machines that defines keyway shapes and measures hole diameters to generate programs ensuring the keyway opening remains accurate, with options for machining paths that prevent narrowing, such as advancing from the bottom toward the opening and forming chamfers or offset paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire electric discharge machining is used for keyway milling to improve productivity compared to slotter machines, then productivity increases, but the keyway opening becomes narrowed due to wire electrode deviation from the machining path
Solution Approach 1:
The patent applies preliminary anti-action by calculating and applying a compensation value to the machining path in advance. The system predicts the deviation caused by discharge repulsion and working fluid forces, then pre-adjusts the machining path to counteract these forces, ensuring the wire electrode follows the intended path and the keyway opening maintains accurate dimensions
Solution Approach 2:
The patent changes the machining parameters by dynamically adjusting the machining path based on calculated compensation values. The system modifies the original machining path parameters to account for forces acting on the wire electrode, transforming the path parameters to prevent opening narrowing while maintaining productivity
2Adaptability or versatility
If operators unfamiliar with wire electric discharge machines create machining programs manually, then device versatility is maintained, but labor time increases and productivity decreases
Solution Approach 1:
The patent implements self-service by enabling the wire electric discharge machine to automatically calculate compensation values and generate optimized machining programs without operator intervention. The system performs self-measurement of forces acting on the wire electrode and self-programming of the machining path, eliminating the time-consuming manual program creation process while maintaining operational flexibility
Solution Approach 2:
The patent applies preliminary action by pre-calculating compensation values and pre-generating machining programs before actual machining begins. The system performs all necessary calculations and program creation in advance, allowing operators to simply load the pre-programmed data and start machining, significantly reducing setup time while maintaining versatility
3Power
If the wire electrode receives forces from discharge repulsion and working fluid during machining, then material removal efficiency improves, but the wire electrode deviates from the machining path causing shape accuracy degradation
Solution Approach 1:
The patent applies the anti-weight principle by calculating the forces of discharge repulsion and working fluid acting on the wire electrode, then determining a compensation value that counteracts these forces. The system creates an opposing adjustment to the machining path that balances the forces, allowing high power material removal while preventing wire electrode deviation and maintaining shape accuracy
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
Significantly improves keyway milling productivity and accuracy, allowing operators to create machining programs that prevent keyway openings from becoming too narrow, ensuring proper key insertion and reducing laborious setup processes.
Implementation Method 1
a keyway is machined on the side surface of a round hole in a workpiece by using a wire electric discharge machine
Implementation Method 2
the sum total (denoted by numeral 12) of a force of discharge repulsion produced in the wire electrode 2
Data Source
Figure 1A
Figure 1B
Figure 2~4
AI summary
A machining program creating device for a wire electric discharge machine creates a machining program for machining a keyway on the side surface of a round hole in a workpiece, based on a previously specified diameter of the round hole, a center position of the round hole measured by bringing a wire electrode into contact with the workpiece, and a previously defined shape of the keyway.