Wire EDM Partial Welding for Part Retention
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Solution Overview
Problem
Conventional wire-cut electrical discharge machining processes require additional steps and devices to prevent cut-out parts from falling, leading to reduced operational efficiency due to the need for manual separation and potential damage during the cutting process, especially with heavy or thick workpieces where the welded spots may not provide sufficient strength to retain the part.
Innovation Solution
The method involves using a wire electrode for spark discharge to cut out parts and then switching to an arc welding phase to create coalescence spots along the cutting path or kerf at preselected areas in the thickness direction of the workpiece, ensuring the cut-out part is securely retained by forming welded spots at multiple locations for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spark discharging is temporarily withheld to leave uncut spots to keep the cut-out part against falling away, then the part is retained on the workpiece, but the operational efficiency is reduced due to additional manual separation steps
Solution Approach 1:
The invention changes the electrical discharge parameters (voltage, current, pulse duration) to control the discharge depth and create controlled uncut spots that serve as retention points. By adjusting these parameters, the system can precisely control where and how deeply the discharge occurs, leaving specific spots unwelded to retain the part while maintaining high operational efficiency through automated control
Solution Approach 2:
The invention performs preliminary action by pre-planning and pre-executing the discharge pattern to create retention spots before the part becomes detached. The system calculates and executes the discharge sequence to ensure parts are retained during cutting, eliminating the need for subsequent manual intervention to prevent part falling
2Productivity
If the spark discharging is completed through to separate the part, then the cutting is finished, but the part may fall away causing damage to the processor, part, or workpiece
Solution Approach 1:
The invention performs preliminary action by pre-calculating and pre-executing discharge patterns that create retention spots before the part can fall. The system determines optimal discharge sequences that complete cutting while maintaining part retention, preventing damage before it can occur
Solution Approach 2:
The uncut spots act as intermediary retention elements between the cutting process and part separation. These spots serve as temporary anchors that hold the part during the cutting process, mediating between the need to complete cutting and the need to prevent part falling and potential damage
3Ease of operation
If manual breaking of uncut spots is performed to separate the part, then the part is released, but additional time is consumed reducing the rate of operation
Solution Approach 1:
The invention makes the system self-service by automatically controlling the discharge sequence to create and then remove retention spots without manual intervention. The system autonomously manages the entire process from cutting to part release, eliminating the need for manual breaking operations and associated time losses
Solution Approach 2:
The invention maintains continuity of useful action by seamlessly integrating the retention spot creation and removal processes into the automated discharge sequence. The system continuously executes discharge operations without interruption for manual intervention, maintaining high operational speed while ensuring part retention when needed
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 securely retains cut-out parts on the workpiece by forming welded spots across multiple locations, preventing falling and enhancing the operational efficiency by eliminating the need for manual separation and reducing the risk of damage during the cutting process, even with heavy or thick workpieces.
Implementation Method 1
spark discharge to cut out parts
Implementation Method 2
cutting a part to be separated from the workpiece with electrical discharge
Implementation Method 3
arc welding to make a coalescence of the part with the workpiece
Implementation Method 4
fusing at least partially the wire electrode and welding the part with the workpiece
Data Source
AI summary
In a method of welding a cut-out part with a workpiece at a preselected area in a thickness direction of the workpiece in a wire electrical discharge machining to retain temporarily or tentatively the part on the workpiece, a wire electrode 5 tilted in posture cuts the workpiece 6 to form a slant cutting surface 30 at a spark discharge location in a desired contour 21 in the workpiece 6. The wire electrode 5 after kept in an upright posture executes the welding process on the workpiece 6 along the slant cutting surface. A plurality of the welded spots is formed over a preselected length at preselected areas in the thickness direction of the workpiece 6. Even if the cut-out part 26 weighs more or the spark discharge is executed on the workpiece 6 overlapped one on the other, the welding spot 20 is formed in the thickness direction of the workpiece 6 adequately depending on the working situation to tentatively retain the cut-out part 26 on the workpiece 6.