Wire EDM Stream Control Mechanism for Fluid Stability
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Solution Overview
Problem
In wire electrical discharge machining, increased wire speed or the number of wires and reduced distance between them can lead to insufficient processing fluid, causing atmospheric discharge and vibration of wires due to the jet flow of processing fluid, resulting in inadequate machining of workpieces.
Innovation Solution
A wire electrical discharge machining apparatus with a processing fluid bath and a stream control mechanism that suppresses the dielectric fluid stream into the bath, ensuring a stable fluid level and preventing direct impact on the wires, thereby maintaining a consistent processing fluid amount between the wire and workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wire speed is increased or the number of wires is increased or the distance between wires is decreased, then the productivity is improved, but the processing fluid becomes insufficient and the wire vibrates due to jet flow
Solution Approach 1:
A stream control mechanism (intermediary component) is introduced between the processing fluid supply and the wire to mediate the fluid flow. This mechanism controls and redirects the jet flow to prevent direct impact on the wire, thereby maintaining wire position stability while allowing high-speed operation
Solution Approach 2:
The harmful jet flow effect is extracted and separated from the beneficial processing fluid function. The stream control mechanism extracts the excessive directional flow that causes vibration while retaining the necessary fluid supply for electrical discharge machining
2Quantity of substance
If the processing fluid is supplied in large flow rate to ensure sufficient processing fluid, then the processing fluid amount is sufficient, but the wire vibrates due to direct jet flow impact
Solution Approach 1:
The processing fluid supply system is segmented into two functional zones: a stream control mechanism that manages flow direction and a processing fluid bath that ensures sufficient fluid quantity. This segmentation allows large flow rates to be supplied without direct jet impact on the wire
Solution Approach 2:
The stream control mechanism acts as an intermediary between the high-flow processing fluid supply and the wire, controlling the flow to prevent direct impact while maintaining sufficient fluid quantity for machining
3Productivity
If the distance between wires is decreased to increase cutting capacity, then the productivity is improved, but the processing fluid becomes insufficient and atmospheric discharge occurs
Solution Approach 1:
The harmful jet flow is extracted and redirected away from the wire region, preventing fluid depletion in the electrical discharge zone even when wires are closely spaced, thereby maintaining reliable electrical discharge
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 solution reduces wire vibration and ensures consistent machining by maintaining a sufficient processing fluid level, allowing for stable and uniform electrical discharge machining of workpieces.
Implementation Method 1
a stream control mechanism configured to be provided to suppress a stream of the dielectric fluid supplied from the dielectric fluid supply port into the dielectric fluid bath in the direction of the water surface of the dielectric fluid in the dielectric fluid bath
Implementation Method 2
the wire electrical discharge machining apparatus machines the workpiece material by electrical discharge such that a wire to which voltage is applied via a power feed contact is allowed to travel and the workpiece material is made close to the wire to cause an electrical discharge phenomenon
Data Source
AI summary
A mechanism in a wire electrical discharge machining apparatus for machining a workpiece by electrical discharge between a wire and the workpiece is disclosed. The mechanism includes a processing fluid bath configured to store processing fluid used for electrical discharge machining between the workpiece and the wire, a processing fluid supply port to communicate with the processing fluid bath and supply the processing fluid into the processing fluid bath from a processing fluid supply apparatus supplying the processing fluid, and a stream control mechanism to suppress a stream of the processing fluid supplied from the processing fluid supply port into the processing fluid bath in the direction of the water surface of the processing fluid in the processing fluid bath.