Wire EDM Turning Tool Rake Face Error Correction
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Solution Overview
Problem
Conventional machining methods for turning tools, especially those using wire electric discharge machines, face challenges in achieving precise shapes due to inclination and waviness errors on the rake face, leading to increased complexity and error in manufacturing and usage, particularly with hard materials like PCD and PCBN tools.
Innovation Solution
A wire electric discharge machine equipped with a measurement unit, error calculation unit, and control unit that measures the inclination and waviness of the tip surface, adjusts the machining trajectory to match the actual surface, ensuring precise machining by calculating correction amounts based on measured errors and taper angles, allowing for precise positioning and alignment of the turning tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jig for inclining and adjusting a tip is used to compensate for rake face errors, then shape accuracy of the machined object can be improved, but device complexity and the number of processes increase
Solution Approach 1:
The invention performs measurement of the rake face shape before machining to detect inclination and waviness errors. By measuring in advance and calculating correction amounts based on measured values and wire electrode taper angle, the system prepares corrected machining trajectories beforehand, eliminating the need for post-measurement adjustment jigs and procedures.
Solution Approach 2:
The invention replaces mechanical adjustment jigs and manual inclination procedures with an automated measurement and calculation system. The numerical control device automatically calculates correction amounts and generates corrected machining trajectories, substituting complex mechanical adjustment equipment with computational correction methods.
2Manufacturing precision
If the tip is inclined to make the rake face closest to the ideal shape, then manufacturing precision can be improved, but ease of operation deteriorates due to complicated adjustment procedures
Solution Approach 1:
The system performs self-measurement and self-correction. The measurement unit measures the actual rake face shape, the calculation unit automatically computes correction amounts based on measured data and wire electrode parameters, and the numerical control device generates corrected machining trajectories without requiring external adjustment operations or manual intervention.
Solution Approach 2:
Manual inclination adjustment operations are replaced by automated measurement and computational correction. The system uses measurement data to calculate and apply corrections through modified machining trajectories, eliminating the need for manual tip inclination procedures and complex adjustment mechanisms.
3Device complexity
If conventional machining with ideal shape trajectories is used, then device complexity is reduced, but manufacturing precision deteriorates due to uncorrected rake face errors
Solution Approach 1:
The invention introduces measurement feedback into the machining process. The measurement unit measures the actual rake face shape, providing feedback data to the calculation unit. This feedback loop enables the system to detect actual deviations from ideal shape and generate corrected machining trajectories that compensate for measured errors, maintaining simplicity while improving precision.
Solution Approach 2:
The system performs preliminary measurement and calculation of correction amounts before actual machining. By measuring the rake face shape in advance and computing corrected trajectories based on measured errors and wire electrode taper angle, the system prepares compensation data beforehand, allowing simple machining operations to achieve high precision through pre-calculated corrections.
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 enables the production of highly precise and easy-to-use turning tools by accurately measuring and correcting for errors in the machining trajectory, reducing the need for complex adjustments and improving the shape accuracy of the rake face, thereby enhancing the precision and usability of the machined blades.
Implementation Method 1
wire electric discharge machine performs machining of an edge part of a turning tool to which a tip is attached by moving a wire electrode relative to a table
Data Source
AI summary
A measurement program for sequentially measuring measurement points, which are to be measured with a touch sensor, is created on the basis of a machining program, which is read in, for machining a turning tool. Then, the rake face height is measured on each of the measurement points and the measurement data is stored. Subsequently, a calculation method of a correction amount is selected so as to calculate the correction amount, and whether or not the calculated correction amount is smaller than a regulation value is determined. The machining program is modified on the basis of the correction amount when the correction amount is not smaller than the regulation value, while the machining program is modified on the basis of the correction amount in accordance with the selected method when the correction amount is smaller than the regulation value.