Wire EDM Power Feed Element Alignment for Thin Plate Cutting
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Solution Overview
Problem
The existing wire electric discharge machining apparatus faces challenges in achieving high accuracy and reliability due to the difficulty in finely adjusting the alignment of power feed elements, which affects the machining precision and productivity when cutting thin plates and semiconductor wafers.
Innovation Solution
The apparatus includes a configuration with pairs of guide rollers and damping guide rollers, where power feed element units are aligned to correspond to the wire parallel arrangement interval, allowing power to be fed to every other wire section, reducing wraparound current influence and improving alignment accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If power feed elements are assembled with high precision alignment to correspond to wire parallel arrangement interval, then machining accuracy is improved, but assembly complexity and adjustment difficulty increase
Solution Approach 1:
The power feed elements are divided into modular units that can be independently assembled and then collectively positioned. Each power feed element unit contains its own power feed elements arranged at fixed intervals, allowing the entire array to be assembled as a standardized module rather than individually adjusting each element, thus reducing assembly complexity while maintaining high alignment accuracy.
Solution Approach 2:
The patent changes the power feed interval parameter from feeding every wire to feeding every other wire (interval of at least every other parallel wire section). This parameter change reduces the number of power feed elements required and simplifies alignment requirements, as fewer elements need to be precisely positioned while still achieving effective machining through the alternating feed pattern.
2Productivity
If power is fed to every wire section individually, then machining productivity is improved, but wraparound current influence increases and machining reliability decreases
Solution Approach 1:
The patent extracts and eliminates the harmful wraparound current effect by changing the power feed pattern. Instead of feeding power to every wire section which causes current to wrap around to adjacent wires, the system feeds power only to every other wire section, effectively removing the source of wraparound current interference and improving machining reliability.
Solution Approach 2:
The power feed is applied in a periodic pattern to every other parallel wire section rather than continuously to all wires. This periodic action creates alternating active and inactive wire sections, which prevents continuous current wraparound while maintaining high productivity through parallel machining of multiple wire sections.
3Manufacturing precision
If power feed elements are closely spaced to match wire intervals, then machining precision is improved, but allowance for fluctuation decreases and alignment becomes more difficult
Solution Approach 1:
The patent changes the spatial parameter of power feed element spacing by introducing an interval of at least every other parallel wire section. This increases the spacing between adjacent power feed elements, providing greater allowance for positional fluctuations and alignment variations while maintaining machining precision through the periodic power feed pattern to alternating wire sections.
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 configuration enhances machining accuracy, simplifies assembly and adjustment, reduces preparation time, and stabilizes power feed, leading to improved machining reliability and productivity for cutting thin plates and semiconductor wafers.
Implementation Method 1
a machining power supply that applies a voltage between the power feed elements and the wire to cause electric discharge
Data Source
AI summary
To perform highly accurate cutting according to stable power feed from a machining power supply, a wire electric discharge machining apparatus includes a wire wound over main guide rollers a plurality of times to simultaneously perform a plurality of kinds of cutting. Wire laying work for a plurality of the wires on power feed elements is reduced, uniform power is fed to cutting wire sections, stable machining is intended, and according to alignment positions, for each of units, a plurality of the power feed elements are aligned to correspond to a wire parallel arrangement interval of the cutting wire sections set as power feed targets and are disposed to feed power to the cutting wire sections with an interval of at least every other cutting wire section.