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Analysis of tool attitude error for a steep taper wire-cut electrical discharge machines using multibody approach

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Abstract

The tool attitude error of steep taper wire-cut electrical discharge machines (EDM) is a significant factor affecting the taper angle error of the workpiece. This study investigated a wire EDM machine that can handle 15° taper through the control of U and V axes. A mathematical model of attitude error is established in the coordinate system of machine tools based on the multi-body approach, considering the coupling relation of parts controlling the movement of the wire. It is found that the positioning error is the major factor contributing to the attitude error by studying the effect of each error component of the U and V axes. Furthermore, the positioning errors of the U-axis and V-axis are close to zero from the very beginning during a 100-mm journey and reach maximum values of 30 µm and 28 µm at 100 mm as the moving distance increases. A comparison experiment is conducted for improving the positioning accuracy of the U and V axes. The results show that the decrease in the positioning error can effectively reduce the volumetric attitude error; attitude error was reduced by 36% in the experiment. Therefore, the mathematical model on tool attitude error is validated.

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Authors and Affiliations

  1. School of Mechanical Engineering, University of Science and Technology, Beijing, Beijing, 10083, China

    Yesong Wang, Ziyue Cui, Yuzhu Kang, Zhixin Jia, Jiang Liu & Changhuai Lyu

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  1. Yesong Wang
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  2. Ziyue Cui
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  3. Yuzhu Kang
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  4. Zhixin Jia
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  5. Jiang Liu
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  6. Changhuai Lyu
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Correspondence to Jiang Liu.

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Wang, Y., Cui, Z., Kang, Y. et al. Analysis of tool attitude error for a steep taper wire-cut electrical discharge machines using multibody approach. Int J Adv Manuf Technol 124, 4143–4158 (2023). https://doi.org/10.1007/s00170-022-09159-3

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  • DOI: https://doi.org/10.1007/s00170-022-09159-3

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