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Abstract
Electric discharge machining (EDM) electrode design has always been an important activity in the die and mould making sector.
Nowadays, softwares are available to design electrodes. Using software, the EDM specialist has to select the areas in the mould cavity
that are to be EDMed. Once the areas are selected, a typical software designs an electrode along with its holder. If the mould cavity is
very complex, as is the case when the mould cavity is pre-machined by high-speed milling, the EDM specialist has to think of several
possible electrode combinations/designs and to select the best solution. He does this based on his knowledge of EDM and the knowledge
of the process capabilities of his EDM machine tool. This paper presents the basic principles of designing a knowledge based system
for automated EDM electrode design. This system works with similar logic, that an experienced EDM specialist would use to design
electrodes. First the overall methodology to design EDM electrodes automatically is described on the highest level. Then the details of this
methodology are explained followed by conclusions.
2004 Elsevier B.V. All rights reserved.
1. Introduction
Today, in order to gain competitive advantage, tool and
die makers make a combined use of conventional technologies like electric discharge machining (EDM) and latest
technologies like high-speed milling (HSM), to reduce lead
times for die and mould manufacture. This combined use of
EDM and HSM is done to take advantage of both the processes in the best possible way. TNO Industrial Technology
in the Netherlands participates in an European Community
project FASTOOL which aims to integrate an EDM machine tool, a HSM machine tool and a robot for automated
die and mould manufacturing. The idea is that the mould
cavity will first be milled on the HSM machine tool followed
by EDMing on the EDM machine tool (if applicable). One
activity in this project is the automated generation of EDM
electrode designs given a mould cavity that is partially
milled, i.e., a pre-milled mould cavity. Besides the FASTOOL project, there are two more motives of developing
such a knowledge based automated system for the design
of EDM electrodes. EDM specialists are difficult to find
Corresponding author. Present address: 3/15 White House Society,
Golf Club Road, Yesawada, Pune 6, Maharashtra State, India.
Tel.: +91-2-06686305.
E-mail address: mpreetam@yahoo.com (K.R. Mahajan).
0924-0136/$ see front matter 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2004.02.007
K.R. Mahajan et al. / Journal of Materials Processing Technology xxx (2004) xxxxxx
Areas to
EDM
Disintegrate areas
to EDM into
distinct regions as
much as possible
EDM
electrodes
Fig. 1. General idea of the method to design electrodes automatically.
n!
a!((n a)!)
K.R. Mahajan et al. / Journal of Materials Processing Technology xxx (2004) xxxxxx
4!
4321
=
=6
2!(4 2)!
22
K.R. Mahajan et al. / Journal of Materials Processing Technology xxx (2004) xxxxxx
Areas to
EDM
Store ALL
the options
(1), (2),(n)
Counter
(1),(n)
Apply
rules
Disintegrate areas
to EDM into distinct
regions as much as
possible
Combine with
next option
Possible
to
combine ?
No
Yes
EDM
electrodes
Save this
option in a
database
EDM
electrodes
Fig. 3. Details of the re-group procedure to re-group different options.
Distances
between
regions to
EDM
EDM
machining
depths
Surface
roughness
required
Criteria for
grouping EDM
electrodes
Machining
times and
costs
EDM
machining
strategy
Manufacturability
of the electrode
K.R. Mahajan et al. / Journal of Materials Processing Technology xxx (2004) xxxxxx
K.R. Mahajan et al. / Journal of Materials Processing Technology xxx (2004) xxxxxx
7. Conclusions
In this paper the basic principles of designing a knowledge based automatic EDM electrode design system were
explained. The success of this system depends to some extent
to the radius detection software algorithm. Although difficult to implement, this software algorithm is not impossible
to realize. In principle the system can also accommodate a
section to predict EDM machining times and the amount of
electrode wear. This would enable to determine the number
of subsequent electrodes needed in view of required geometric accuracy of the cavity. Some preliminary work in these
directions has been performed but many particularities of
EDM machining have to be researched. Outside the FAS-