Wire EDM Taper Machining via Workpiece Tilting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wire electric discharge machines face challenges in taper machining, including reduced machining speed, compromised accuracy due to frictional forces, precision issues with varying supporting points, difficulty in setting machining conditions, and potential wire electrode disconnection or exceeding movable ranges, particularly when the wire electrode is stretched obliquely.
Innovation Solution
A wire electric discharge machine that mounts the workpiece at an angle and transforms the coordinate system to keep the wire electrode substantially perpendicular to the table surface, allowing for efficient sludge discharge, reduced friction, improved precision, and optimized machining conditions by adjusting the plate thickness and correcting machining command values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the wire electrode is stretched obliquely for taper machining, then the desired tapered shape can be obtained, but machining speed reduces and sludge discharge becomes inefficient
Solution Approach 1:
Instead of tilting the wire electrode to achieve taper machining, the invention inverts the approach by keeping the wire electrode vertical and tilting the workpiece instead. This allows the wire to remain perpendicular to the table surface for efficient sludge discharge while still achieving the desired tapered shape through coordinate system transformation and workpiece orientation.
Solution Approach 2:
The invention transitions from two-dimensional wire electrode tilting to three-dimensional workpiece orientation. By rotating the workpiece around a vertical axis and transforming the coordinate system, the taper machining is achieved through workpiece positioning rather than wire electrode angling, maintaining vertical wire configuration for optimal performance.
2Shape
If the wire electrode is stretched obliquely for taper machining, then the desired tapered shape can be obtained, but frictional forces compromise machining accuracy
Solution Approach 1:
The invention inverts the conventional approach by keeping the wire electrode vertical and eliminating oblique stretching. This removes the source of frictional forces that compromise accuracy, while the desired tapered shape is still achieved through coordinate system transformation and workpiece orientation rather than wire angling.
3Shape
If the wire electrode is stretched obliquely for taper machining, then the desired tapered shape can be obtained, but precision issues arise due to varying supporting points
Solution Approach 1:
Instead of varying the wire electrode's supporting points through oblique stretching, the invention keeps the wire vertical with fixed supporting points. The tapered shape is achieved by transforming the coordinate system and orienting the workpiece, thereby eliminating precision issues related to varying supporting points.
4Shape
If the wire electrode is stretched obliquely for taper machining, then the desired tapered shape can be obtained, but wire electrode disconnection or exceeding movable ranges may occur
Solution Approach 1:
The invention eliminates oblique wire stretching that causes disconnection and range-exceeding problems. By keeping the wire vertical and achieving taper through workpiece orientation and coordinate transformation, the wire remains within safe operational parameters and maintains stable connection throughout the machining process.
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 enhances machining speed, accuracy, and precision, reducing the likelihood of wire electrode disconnection and exceeding movable ranges, while allowing for efficient taper machining without the need for complex program revisions.
Implementation Method 1
a voltage is applied to a wire electrode 4 stretched between an upper wire guide 12 in an upper nozzle 10 and a lower wire guide 13 in a lower nozzle 11, and a workpiece 3 fixed on a workpiece table 1, which is driven relative to the wire electrode 4, is moved along two axes, X- and Y-axes (not shown), which perpendicularly intersect each other on a horizontal plane. Grooving is performed to obtain a desired machining shape by melting and removing the workpiece 3 by continuous electric discharge caused (in a machining gap) between the wire electrode 4 and the workpiece 3.
Data Source
AI summary
In a wire electric discharge machine, a workpiece mounting unit mounts a workpiece tilted at a preset angle to a plane based on two orthogonal axes, X- and Y-axes. An XY-coordinate system is tilted at the preset angle so that it is transformed into an X′Y′-coordinate system. A machining command value commanded by a machining program is corrected based on the X′Y′-coordinate system. Thus, the tilted workpiece is taper-machined with a wire electrode kept substantially perpendicular to the XY-plane (table surface).