machining of sharp corners using rotating tools

Rotating Curvilinear Toolsfor EDM of

Polygonal Shapes with Sharp Corners

Y. Ziada, P. KoshyMcMaster University, Canada

57th CIRP General Assembly, DresdenAugust 21, 2007

Rotating Curvilinear Tools for EDM of Polygonal Shapes with Sharp CornersY. Ziada, P. Koshy

57th CIRP General AssemblyDresden, Germany, August 21, 2007

Flushing of the interelectrode gap is of critical importance in EDM processes, in regard to machining productivity and machined surface quality

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Several techniques can be used to facilitate flushing in EDM

through-tool forced flow

jump EDM

jet flushing

horizontal EDM

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Another approach to flushing is to induce a relative motion between the electrodes

ED-millingplanetary EDM

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The present work involves kinematic aspects of rotating curvilinear tools for sinking cavities with sharp corners

rotating

sharp corners

toolscurvilinear

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Reuleaux Triangle

s

1

23

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Reuleaux Triangle is a curve of constant width that can rotate inside a square

s

s

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Kinematics of a Reuleaux Triangle

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For every revolution of the Reuleaux Triangle, the centroid traverses the orbit three times in the opposite direction

The swept area is 98.8% of that of the square

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The area of a Reuleaux Triangle is 70.5% of that of the squareA circular tool for machining a similar corner will only be 4% of the area of the square

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Replacing the complex orbit with a circular one facilitates implementation on a machine tool with a single servo-controlled axis, and entails a maximum profile deviation of only 0.003s

25 mm

c)

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Reuleaux Triangle tools correspond to improved removal rates and better surface quality

b)

arcing

Stationary

25 mm

c)

RT

25 mm

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Machining of a square with a sharp corner using Reuleaux Triangle tools involves modifications to tool shape and tool path

k = 1.93 for an included angle of 90 degrees

≈s ks ≈s ksks

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Modification to tool pathY

0.034

number of sides

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Machining of a square with a sharp corner

Locus magnified 2X

10 mm

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Extension of the concept to machine regular polygons

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Machining of a hexagon

Locus magnified 2X

5 mm

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Machining of a non-regular polygon

Locus magnified 2X

5 mm

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Machining of a triangle

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Conclusions

Innovative kinematic schemes motivated by the concept of Reuleaux Triangle for the seemingly impossible task of using rotating tools to sink polygonal shapes with sharp corners are presentedApplication of the technology enhances gap flushing while maximizing the frontal machining areaEfforts are required to address tool wear issues resulting from the adverse geometric relative duty of Reuleaux Triangle toolsThe work represents a significant advance towards exploiting the capabilities of CNC ram EDM

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Thank youfor your kind attention!

machining of sharp corners using rotating tools

Technology