Software and hardware design of a robotic manipulator for the manufacture of complex shaped dies

Abstract

Metal forming dies can be manufactured by various conventional and nontraditional methods. Dies for drawing and extrusion of complex cross-section components are usually difficult to manufacture by traditional methods, and in many cases Wire Electro Discharge Machining ( WEDM ) technique is found to be suitable. Currently WEDM machines with integral CNC systems are commercially available. However, these machines are very expensive and have limited angular machining facilities. A precision robotic manipulator, which is independent of the machine would be more versatile and cheaper. The present paper describes the design and commissioning aspects of such a manipulator. This four axes manipulator has two linear and two rotational movements facilitated by A.C. servomotors, which in turn are controlled using micro-computer based softwares. The complex shapes are generated by precision manipulation of the workpiece through appropriate software. Tests have been carried out using model materials and simulated WEDM. The principal application would be in machining of dies or components having 3-dimensional external and / or internal surfaces.