Abstract
Due to the structural limitation and the deterioration of the flushing condition caused by wire tilting, it is difficult for the traditional “X-Y-U-V” type wire electrical discharge machining (WEDM) to machine workpieces with a taper larger than 30°. In order to improve the surface quality and dimensional accuracy of the workpieces with a larger taper, a cradle-type WEDM configuration, in which the workpiece swings rather than the wire tilting is proposed. Firstly, a kinematic model for solving the numerical control instructions of the machine tool is established based on this configuration. Then the geometric errors of the machine tool are taken into account for accuracy modeling, and a mapping relationship between these errors and the machined surface is deduced. Finally, wire-EDM experiments are conducted to verify the feasibility of the proposed cradle-type WEDM for machining workpieces with a large taper, and the dimensions of the machined workpiece are measured to verify the plausibility of the error model.
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