Wire EDM Support Assembly Using Conductive Wax for Part Liberation
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Solution Overview
Problem
The existing methods for liberating parts from a build plate using wire electrical discharge machining (EDM) in direct laser metal sintering face challenges such as short circuits, part damage, machine damage, and jamming due to the lack of support during the liberation process, which requires post-operation machining and can halt production.
Innovation Solution
A support assembly for wire EDM that includes a build plate with a temporary support and a layer of support material, such as conductive wax, which is solidified to hold the parts in place during machining and melted for easy removal, minimizing the risk of short circuits and damage while allowing for consecutive machining passes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If parts are liberated from the build plate by wire EDM without support, then the parts can be removed from the base plate, but short circuits occur that stop the EDM process or break the wire
Solution Approach 1:
A support structure made of conductive material (such as copper or brass) is introduced as an intermediary between the part and the build plate. This support structure provides electrical continuity during the EDM process, preventing short circuits while allowing the part to be securely held and subsequently removed.
Solution Approach 2:
The support structure is prepared and positioned on the build plate before the EDM liberation process begins. This preliminary setup ensures that electrical continuity is established in advance, preventing short circuits during the machining operation and eliminating the need for operator intervention.
2Reliability
If parts are held firmly during wire EDM liberation, then short circuits are minimized, but the parts require post-operation machining to remove tabs
Solution Approach 1:
The support structure is designed as a separate, removable component that can be easily extracted from the part after the EDM liberation process. This extraction eliminates the need for additional machining operations to remove tabs, as the support structure itself is the tab that is simply pulled away from the finished part.
3Ease of manufacture
If parts are allowed to fall during liberation, then the machining process is simpler, but the parts and machine may be damaged from impact
Solution Approach 1:
The support structure serves as a cushioning element that prevents the part from free-falling during the liberation process. By maintaining physical support until the liberation is complete, the system eliminates impact damage to both the part and the machine while keeping the process simple and automated.
4Object-affected harmful factors
If parts are supported during wire EDM, then damage is minimized, but the support structure may jam the lower arm of the wire EDM
Solution Approach 1:
The support structure is designed as a segmented or modular component with features that allow the wire EDM lower arm to pass through or around it. This segmentation enables the support structure to provide necessary support during machining while preventing interference with the machine's moving components, eliminating jamming risks.
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 effectively reduces the occurrence of short circuits, eliminates the need for post-operation tab removal, minimizes part and machine damage, and mitigates jams, enabling efficient and reliable part liberation with improved finishing capabilities.
Implementation Method 1
disposing a chilled fluid in the cavity of the layering basin to solidify the support material and form at least one solid layer of support material for supporting the at least one additive manufactured part
Implementation Method 2
supplying a hot fluid into the body of the removal basin to liquify the at least one layer of the support material
Data Source
AI summary
A support assembly for wire EDM includes a build plate, a temporary support, and at least one layer of a support material. The build plate has a body. The body has at least one additive manufactured part disposed on the body. The temporary support is removably disposed on the build plate. The temporary support has a hollow body defined by a plurality of sidewalls. The plurality of sidewalls have a plurality of apertures. The at least one layer of the support material is disposed on the build plate and the temporary support. The at least one layer of support material is a conductive wax material. The at least one layer of support material is configured to be melted and reused in subsequent wire EDM processes.