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Research Papers

Setup Planning Automation for Six-Axis Wire Electrical Discharge Machining

[+] Author and Article Information
Zhi Yang

Department of Industrial and Manufacturing Engineering,  The Pennsylvania State University, University Park, PA 16802wityang@gmail.com

Richard A Wysk

Department of Industrial and System Engineering,  North Carolina State University, Raleigh, NC 27695

Sanjay Joshi

Department of Industrial and Manufacturing Engineering,  The Pennsylvania State University, University Park, PA 16802

J. Manuf. Sci. Eng 134(2), 021009 (Apr 04, 2012) (10 pages) doi:10.1115/1.4005801 History: Received February 01, 2011; Revised December 03, 2011; Published March 30, 2012; Online April 04, 2012

A modern six-axis wire electrical discharge machining (WEDM) system is capable of producing more complex geometries than 2D, 2½D, or ruled surface parts. The rotational axis on a six-axis WEDM system allows a part to be rotated while using a cutting wire to fabricate it. However, limited automation for process planning six-axis WEDM systems requires significant time and effort must be put into process planning. Even with commercially-available computer-aided design (CAD ) software, it is difficult to produce process plans for a six-axis WEDM system. Toward automatic development of process plans, a method of determining such setup plans, including the number of setup orientations and rotational axis movements, is presented in this paper. Tangent visibility analysis results presented in our prior research are used to guide the setup, and intermediate coordinate systems are defined in order to classify the tangent visibility results. A greedy algorithm is developed to determine the set of intermediate coordinates and setup orientations for six-axis WEDM.

Copyright © 2012 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Six-axis wire electrical discharge machining design

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Global tangent visibility results

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The polygon combination procedure

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A coordinate system for WEDM-RP

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Definitions of RN and RO

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Visibility straight line results for pagoda model

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Example of an intermediate coordinate and a manufacturing coordinate

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Edge and RN Relationship

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All coverable lines under certain rotational norms (RN)

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Example of a polygon without concave edges

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Facet norm and OP relationship

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Coverable polygon norms for a given OP

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Figure 14

Flowchart for determining intermediate coordinate systems

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An example of an initial RO with its RN′s

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An example of an initial RN with its RO′s

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Figure 17

Flowchart for calculating initial RN

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Flowchart for calculating initial RO

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Figure 19

Flowchart for classification of tangent visibility results

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Figure 20

Flowchart for FindRNRoEdge procedure

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Details for FindRNRoFct

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Figure 23

Slot island model

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Figure 26

Manufacturing setup

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