Wire EDM Rake Face Positioning for Ultra-Hard Cutting Tools
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Solution Overview
Problem
Conventional wire electric discharge machining methods for cutting tools with ultra-hard materials like polycrystalline diamond (PCD) and cubic boron nitride (PCBN) face challenges in achieving high precision due to measurement errors and complex shape machining, particularly with curved or spiral rake faces, leading to inefficiencies and increased costs.
Innovation Solution
A wire electric discharge machining method and machine that utilize a touch sensor or contactless sensor to measure and correct the position of the rake face along a machining path, allowing for precise machining by generating and regenerating machining programs based on measured coordinates, enabling accurate formation of cutting blades with complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional wire electric discharge machining is used to machine ultra-hard materials like PCD and PCBN, then the cutting tools can be manufactured, but measurement errors and complex shape machining difficulties lead to poor precision
Solution Approach 1:
The patent implements feedback by using a touch sensor to detect the actual rake face position during machining, then feeding this information back to correct the machining path in real-time. The system measures the rake face position at multiple points along the machining path and adjusts the wire electrode position based on detected deviations, thereby eliminating measurement errors and improving cutting tool precision.
2Measurement precision
If a touch sensor is introduced to measure rake face position, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The touch sensor serves multiple functions: it acts as both a measurement device for detecting rake face position and as a feedback mechanism for correcting machining errors. By integrating these functions into a single component, the system achieves high measurement accuracy without proportionally increasing overall device complexity.
3Manufacturing precision
If accurate rake face position measurement is performed at multiple points, then machining precision improves, but machining time increases
Solution Approach 1:
The system performs preliminary measurement of the rake face position at multiple points along the machining path before actual machining begins. This preliminary action allows the system to pre-calculate correction values and generate an adjusted machining path, thereby eliminating the need for time-consuming measurements during the actual machining process while still achieving high precision.
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 significantly reduces measurement errors and operator burden, enabling high-precision machining of cutting tools with ultra-hard materials by accurately positioning the wire electrode and rotating shaft, thus improving the precision and longevity of the cutting tools.
Implementation Method 1
electric discharge machining methods in which a PCD material is machined through burning by exploiting phenomena
Implementation Method 2
wire electric discharge machining, in which cutting proceeds along a machining path alone
Implementation Method 3
a touch sensor is mounted to the upper wire guide
Implementation Method 4
causing the rotating shaft, to which the cutting tool is mounted, to rotate in a direction in which a face of the ultra-hard material being fixed to the cutting tool, that forms a tool rake face comes into contact with the probe end section
Implementation Method 5
forming a cutting blade through wire electric discharge machining of the ultra-hard material by the wire electrode
Data Source
AI summary
An ultra-hard material fixed to a cutting tool is formed into a cutting blade by electric discharge machining. The wire electric discharge machine has a rotating shaft to which the cutting tool is mounted, and has a touch sensor mounted to an upper wire guide. A measurement program is generated on the basis of a machining path instructed by the machining program. A machining program is regenerated from rotating shaft coordinate information and path coordinate position information obtained at measurement points, on the basis of the measurement program. As a result, a rake face position of the cutting tool can be accurately measured and a wire electrode can be positioned accurately with respect to that position during machining.