Wire EDM Program Device for Vertical Electrode Taper Machining
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Solution Overview
Problem
Conventional wire electric discharge machining with obliquely stretched wire electrodes faces issues such as reduced machining speed due to sludge discharge difficulties, surface roughness from frictional forces, precision challenges due to varying wire electrode support points, and complex machining condition settings, especially as the taper angle increases.
Innovation Solution
A machining program creating device for a wire electric discharge machine equipped with a loading unit using two or more pivots, allowing for arbitrary workpiece tilting, synchronizes the movement of linear axes and pivots to maintain the wire electrode vertical, thereby creating a machining program that adjusts the workpiece tilt relative to the wire electrode, improving machining accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wire electrode is stretched obliquely for taper machining, then the taper angle can be achieved, but the machining speed cannot be increased due to difficulties in discharging sludge
Solution Approach 1:
Instead of tilting the wire electrode to achieve the taper angle, the invention inverts the approach by keeping the wire electrode vertical and tilting the workpiece using a loading unit with pivots. This inversion resolves the sludge discharge problem while maintaining taper machining capability.
Solution Approach 2:
The loading unit is designed with pivots that enable dynamic tilting of the workpiece during machining. The workpiece can be tilted to the required angle relative to the vertical wire electrode, allowing taper machining to be performed while maintaining optimal sludge discharge conditions.
2Manufacturing precision
If the wire electrode is stretched obliquely for taper machining, then the taper angle can be achieved, but high-precision is difficult due to varying supporting points of the wire electrode
Solution Approach 1:
The invention inverts the approach by maintaining the wire electrode in a vertical position with fixed supporting points, and instead tilting the workpiece to achieve the desired taper angle. This inversion stabilizes the wire electrode position and improves machining precision.
3Manufacturing precision
If the wire electrode is stretched obliquely for taper machining, then the taper angle can be achieved, but it is difficult to set machining conditions
Solution Approach 1:
The invention simplifies machining condition setting by inverting the conventional approach: the wire electrode is kept vertical with standard machining parameters, while the workpiece is tilted using the loading unit. This allows use of established vertical machining parameters while achieving taper machining.
Solution Approach 2:
The invention changes the parameter being adjusted from wire electrode tilt angle to workpiece tilt angle. This parameter transformation simplifies the control system and allows independent optimization of wire electrode parameters while achieving the desired taper angle through workpiece orientation.
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
When graphic information is selected, program creating unit (82) receives machining shape data from graphic information analysis unit (81) and pivot axis information from rotation center storage unit (83). Based on the received data, the program creating unit (82) generates a new amount of movement of a wire electrode relative to a workpiece and the amounts of rotation of pivots, used to machine the workpiece with the wire electrode held vertical.