Wire EDM Run-Out Correction for Cutting Tools
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Solution Overview
Problem
Conventional wire electric discharge machining methods face challenges in achieving high precision due to rotational run-out errors in cutting tools, particularly when using PCD or PCBN materials, as existing methods require labor-intensive and time-consuming adjustments to maintain acceptable rotational run-out accuracy, and are not effective for tools with incomplete cylindrical outer circumferences or multiple cutting blades.
Innovation Solution
A method and machine system that measures the position of a cutting tool's blade face using a touch sensor or non-contact position detecting device, creates a machining program to correct rotational run-out errors by calculating center coordinates and run-out errors at multiple rotation angles, and adjusts the machining path to cancel these errors, eliminating the need for manual position adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual position adjustment is performed to maintain rotational run-out accuracy within acceptable limits, then manufacturing precision is improved, but loss of time and productivity deteriorate due to labor-intensive adjustment operations
Solution Approach 1:
The system automatically measures rotational run-out using a touch sensor or non-contact position detecting device and calculates correction amounts without manual intervention. The machining program self-corrects for run-out errors by incorporating calculated position adjustments, eliminating the need for expert manual adjustment operations while maintaining high precision within acceptable limits
Solution Approach 2:
Manual mechanical adjustment operations are replaced by an automated measurement and calculation system. The touch sensor or non-contact position detecting device measures run-out, the control unit calculates correction amounts, and the machining program automatically incorporates these corrections, substituting human expertise with automated computational processes
2Device complexity
If three-jaw chuck or four-jaw chuck is used for tool attachment, then device complexity is reduced, but manufacturing precision deteriorates due to rotational run-out errors
Solution Approach 1:
The system accepts that rotational run-out will occur when using simple three-jaw or four-jaw chucks, but converts this harmful effect into a beneficial correction by measuring the actual run-out and incorporating position adjustments into the machining program. This allows simple fixing mechanisms to achieve high precision through computational compensation
Solution Approach 2:
The machining program dynamically adjusts position parameters based on measured run-out characteristics. By changing the machining path coordinates to compensate for run-out, the system maintains manufacturing precision while allowing the use of simpler, less expensive fixing mechanisms
3Loss of time
If detachable collet holder is used to reduce adjustment operations, then loss of time is reduced, but device complexity and cost increase due to multiple expensive collets required
Solution Approach 1:
The automated measurement and correction system works with any tool holding mechanism, making the run-out compensation capability universal. This eliminates the need for specialized expensive collets, as the same touch sensor-based measurement and program correction approach can be applied regardless of the fixing mechanism used
4Manufacturing precision
If position adjustment is performed every time a tool is exchanged, then manufacturing precision is maintained, but productivity deteriorates due to repeated adjustment operations
Solution Approach 1:
The system automatically performs run-out measurement and correction calculation for each tool without requiring manual adjustment operations. The touch sensor measures the tool's run-out characteristics, the control unit calculates position corrections, and the machining program is automatically updated, maintaining precision while eliminating time-consuming manual adjustment steps during tool exchanges
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 man-hours required for maintaining rotational run-out accuracy, enabling the creation of high-precision cutting tools with low rotational run-out errors, even with less expensive fixing methods, and is applicable to tools with complex geometries like those with multiple cutting blades and incomplete cylindrical outer circumferences.
Implementation Method 1
wire electric discharge machining method for machining, with high precision, a rotating-type cutting tool
Implementation Method 2
measuring a position of a blade face in a cutting tool attached to a rotary axis by a touch sensor
Data Source
AI summary
In a wire electric discharge machine that machines a blade section of a cutting tool, in a state in which a rod-shaped reference jig is fixed to a rotary axis, a position on an outer circumferential surface of the reference jig is measured at each rotation position and stored. A rotational run-out error is calculated based on the stored rotational run-out position information, and a machining program is corrected to cancel the rotational run-out error.