SpringerLink
Log in

Original models for the prediction of angular error in wire-EDM taper-cutting

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Taper-cutting is a common application of the wire electrical discharge machining (WEDM) process used for the production of parts with complex geometry such as extrusion dies in wear-resistant materials, cutting dies, etc. During cutting, the wire is subject to deformation, resulting in deviations in the inclination angle of machined parts. This fact causes dimensional errors and loss of tolerances that can lead to the rejection of high added-value tooling. Currently, WEDM machine manufacturers propose time-consuming experimental trial-and-error methodologies for the correction of the errors. To reduce the experimental load and to contribute a more general approach to the problem, two original models for the prediction of angular error in WEDM taper-cutting are presented here. Results show that part thickness and taper angle are the most influencing variables in the problem. Experimental validation of the proposed models shows that angular error can be reduced below 3′45′′ in 75% of cases.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Van Dijck F (1973) Physico-mathematical analysis of the electro-discharge process. Ph. D. Thesis, K.U. Leuven

  2. Dekeyser WL, Snoeys R (1989) Geometrical accuracy of wire EDM. Int. Symposium on Electro Machining (ISEM) IX, 226–232

  3. Dauw DF, Beltrami I (1994) High-precision wire EDM by on-line wire position control. Annals of the CIRP, 43/1/94, 193–197

    Google Scholar 

  4. Han F, Kunieda M, Sendai T, Imai Y (2002) Simulation on influence of electrostatic force on machining characteristics in WEDM. Int J Electr Mach 7:31–36

    Google Scholar 

  5. Magara T, Yamada H, Yatomi T, Kobayashi K (1994) Study on improvement of surface straightness in wire EDM. Precis Eng 16(2):156–161

    Google Scholar 

  6. Dauw DF, Sthioul H, Delpretti R, Tricarico C (1989) Wire analysis and control for precision EDM cutting. Annals of the CIRP, 38/1/89, 191–194

    Google Scholar 

  7. Sthioul H, Delpretti R, Tricarico C, Dauw DF (1989). Improvement of the wire EDM cutting precision by vibration analysis and control. Int. Symposium on Electro Machining (ISEM) IX, 214–218.

  8. Yamada H, Mohri N, Saito N, Magara T, Furutani K (1997) Modal analysis of wire electrode vibration in wire-EDM. Int J Electr Mach 2:19–24

    Google Scholar 

  9. Puri AB, Bhattacharyya B (2003) An analysis and optimisation of the geometrical inaccuracy due to the wire lag phenomenon in WEDM. Int J Mach Tools Manuf 43:151–159. doi:10.1016/S0890-6955(02)00158-X

    Article  Google Scholar 

  10. Ravani B, Wang J (1991) Computer aided geometric design of line constructs. ASME J Mech. Des 113(4):363–371. doi:10.1115/1.2912791

    Article  Google Scholar 

  11. Wang J, Ravani B (2003) Computer aided contouring operation for travelling wire electric discharge machining (EDM). Comput Aided Des 35:925–934. doi:10.1016/S0010-4485(02)00207-5

    Article  Google Scholar 

  12. Richard J, Nguyen VK, Stroud I (2004) Standardisation of the manufacturing process: IMS/EU STEP-NC project on the wire EDM process, IMS Forum, part 2, 1197–1204

  13. Hsue WJ, Su H (2004) Removal analysis of WEDM’s tapering process and its application to generation of precise conjugate surface. J Mater Process Technol 149:117–123. doi:10.1016/j.jmatprotec.2004.03.001

    Article  Google Scholar 

  14. Chiu YY, Liao YS, Li HC, Sue PC (2007) Study of taper-cut machining of WEDM machine. Proc. of the 2nd Manufacturing Engineering Society International Conference, Madrid

  15. Kinoshita N, Fukui M, Fujii T (1987) Study on wire-EDM: accuracy in taper-cut. Annals of the CIRP, 36/1/87, 119–122

  16. Kinoshita M (1997) Control device for wire electric discharge machining with taper working correction function. Patent JP11165219A

  17. Diamond WJ (1989) Practical Experiment Designs, 2nd edn. Van Nostrand Reinhold, New York

    Google Scholar 

  18. Sanchez JA, Plaza S, Lopez de Lacalle LN, Lamikiz A (2006) Computer simulation of wire EDM taper-cutting. Int J Comput Integr Manuf 19:727–735. doi:10.1080/09511920600628855

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering of Bilbao, Alameda de Urquijo s/n, 48013, Bilbao, Spain

    S. Plaza, N. Ortega, J. A. Sanchez & I. Pombo

  2. Ideko, S. Coop., Arriaga kalea 2, 20870, Elgoibar, Spain

    A. Mendikute

Authors
  1. S. Plaza
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. N. Ortega
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. J. A. Sanchez
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. I. Pombo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. A. Mendikute
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to S. Plaza.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Plaza, S., Ortega, N., Sanchez, J.A. et al. Original models for the prediction of angular error in wire-EDM taper-cutting. Int J Adv Manuf Technol 44, 529–538 (2009). https://doi.org/10.1007/s00170-008-1842-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-008-1842-5

Keywords

Search

Navigation