Conceptual Design of a High-Speed Wire EDM Robotic End-Effector Based on a Systematic Review Followed by TRIZ
Abstract
:1. Introduction
2. Materials and Methods
2.1. Systematic Literature Review
2.2. Combination Scenarios
2.3. Innovative End-Effector Ideation by TRIZ
3. Results and Discussion
3.1. State of the Art in EDM Machining
3.1.1. EDM Fundamentals
3.1.2. EDM Variant Processes
- HS-WEDM refers to a new high-speed wire electrical discharge machining (HS-WEDM) and has been broadly adopted due to its cost-effectivity. It defers from conventional LS-WEDM due to the wire running faster and being reused [32]. In HS-WEDM, the wire performs a reciprocating motion with a speed up to 12 m/s, which is on average ten times more than LS-WEDM. The wire is usually made of molybdenum or tungsten molybdenum alloy with diameters from 0.08 to 0.25 mm [64]. As a drawback, while LS-WEDM can reach an MRR of 500 mm2/min, the stable MRR in HS-WEDM is usually 100 mm2/min, but no more than 200 mm2/min [63].
- Lately, cylindrical wire electrical discharge turning (CWEDT) is a particular form of WEDM where a submerged rotation spindle work as a clamping device for workpiece rotation to cylindrical machine parts [67].
3.1.3. EDM Systematic Literature Review
3.2. State of the Art in IR Machining
3.2.1. Industrial Robots (IR) Fundamentals
3.2.2. IR Systematic Literature Review
4. Narrowing Potential Combinations
4.1. Combination Plausibility Calculation and Discussions
4.2. Innovative End-Effector Ideation Based on TRIZ
4.3. WEDM End-Effector
- Six-axis IR robot control ABB—IRB 2400 with payload 10–16 kg and reach of 1.55 m
- Wire EDM pulse generator
- Dielectric cooling and flow control
- Wire tension control
- Wire-speed control
- In Figure 13a, a high-speed reciprocating wire EDM unity can use a range of wires diameters from 0.15 to 0.3 mm and speed from 0.1 to 12 m/s. The system embodied a mechanical wire winding system that guarantees perfect synchronism between the wire portion being released and tractioned. Moreover, the servo motor is built inside the wire drum, with the motion being transferred by gears. As a result, this approach has provided a compact design with lower collisions risks and more significant envelop usage, as well as appropriate gravity centre to the end-effector.
- In Figure 13b, a holding structure optimised by topologic analysis and internal hollow lattice structure allows for flowing the dielectric through the structure to cool the workpiece and the structure and sensitive components such as the tension control. Moreover, the structure is designed so that the exposed wire electrode is 600 mm large, which is nearly the limit of most WEDM machines cutting thickness in the market.
- In Figure 13c, the tension breaker can provide uniform tension up to 30 N. This allows creating a magnetic field controlled by coil current based on ferromagnetic powder, providing constant tension independently of positioning or wire direction of wire speed. Moreover, the pulley design incorporates a propeller that generates an airflow to cool the system and helps to reduce contact with dielectric fluid or debris;
- In Figure 13d, we have a high-frequency piezoelectric actuator able to work in two directions (X, Y) to provide a wide range of ultrasonic wire excitation in frequency and combined wave orientation. Hence, the actuator works to promote automatic, fast, and accurate wire retraction and repositioning in the case of wire short-circuit.
- Still, in Figure 13d, it is possible to see that conductive graphite brushes are adopted to provide continuous and stable electric power transition to the wire. Hence, it is expected and yet to be confirmed if this approach can reduce wire erosion by filling wire craters with graphite conductive material. Moreover, the titanium pulleys are designed with deep grooves and self-centred bearings to avoid wear, vibration, and wire run-out.
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Conflicts of Interest
Abbreviations
A.H.P. | Analytic Hierarchy Process |
C.N.C. | Computer Numeric Control |
D.O.F. | Degrees of freedom |
EDM | Electric Discharge Machining |
EE | End Effector tool |
EWR | electrode wear rate |
IR | 6 Axis Industrial Robot |
M.P.T. | Methods, Processes and Tools |
M.R.R. | Material Rate Removal |
PM-EDM | Powder-mixed electrical discharge machining |
SR | Surface roughness |
SWOT | Strengths, Weaknesses, Opportunities and Threats |
T.R.I.Z. | Theory of inventive problem-solving technique |
W.E.D.M. | Wired Electro Discharge Machining |
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Preliminary Research Strings | Final Research Strings | ||
---|---|---|---|
E.D.M. | IR machining | E.D.M. | IR machining |
Exotic material | Machining | Exotic material | Six axis robots |
Electric discharge | Robotic | Hard to cut material | Industrial robot |
Hard to cut | Hard to cut | Electric discharge | Wire cut |
EDM | EDM | Machining | |
Wire EDM | Grinding | ||
High-speed WEDM |
Main Targets | Used Means | M.P.T.s | Deliverable | ||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Year | Reference | Material Rate Removal | Surface Roughness | Wire Performance | Design Freedom | Accuracy | Process Optimisation | Electrode Speed or Composition | Process Prediction | Dielectric Composition | Taper Angle | Methods | Processes | Tools | |
2010 | [75] | ✔ | ✔ | ✔ | Review on wire electrodes | ||||||||||
2012 | [76] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation of 6061Al/Al2O3p/20p Al composite | |||||||
[57] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Review on many powders as additives in EDM dielectric | ||||||||
2014 | [77] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Review on process optimisation | |||||||
2015 | [46] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Review on wire electrodes | ||||||
[78] | ✔ | ✔ | ✔ | ✔ | ✔ | Explains the influence of thickness, current and wire-speed on SR | |||||||||
[79] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for SR based on current, wire speed and Ø | ||||||||
[32] | ✔ | ✔ | ✔ | ✔ | Design of real-time system control for MRR, SR and stability | ||||||||||
[80] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation by Adaptive neuro-fuzzy inference system | |||||||||
[81] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for SR and MRR with minimum cost | ||||||||
[82] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for taper cutting | |||||||||
[83] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for Nimonic-263 alloy | |||||||||
[84] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for HSLA steel | ||||||||
[85] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for HCHCr | ||||||||
[86] | ✔ | ✔ | ✔ | ✔ | ✔ | A tool and a method for process optimisation | |||||||||
[58] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Mirror surface finishing by nanotubes & dielectric mix | |||||||
[87] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Improved SR and MRR by pulse generators in high frequency | ||||||||
[88] | ✔ | ✔ | ✔ | ✔ | Dielectric fluid for hydrophobic material | ||||||||||
[47] | ✔ | ✔ | ✔ | ✔ | Real-Time system for MRR | ||||||||||
[89] | ✔ | ✔ | ✔ | ✔ | Wire servo system to cope with semiconductors | ||||||||||
2016 | [36] | ✔ | ✔ | ✔ | ✔ | ✔ | Pulse on time as most significant for MRR and SR | ||||||||
[45] | ✔ | ✔ | Review on EDM for machining curved hole | ||||||||||||
[90] | ✔ | ✔ | ✔ | ✔ | Prediction accuracy 93.62% for SR and MRR | ||||||||||
[91] | ✔ | ✔ | ✔ | ✔ | ✔ | Clarify wire movements and suggest workpiece location | |||||||||
[92] | ✔ | ✔ | ✔ | ✔ | ✔ | Maximized WEDM cutting speed | |||||||||
[93] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for INCONEL 600 | |||||||||
[3] | ✔ | ✔ | ✔ | ✔ | ✔ | Explains wire deformation and degradation | |||||||||
[94] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Review on EDM applications of ultrasonic vibrations | ||||||||
[95] | ✔ | ✔ | ✔ | ✔ | Process optimisation for metal matrix composite | ||||||||||
[96] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for tapered parts | |||||||
[63] | ✔ | ✔ | ✔ | ✔ | ✔ | Burning courses in HS-WEDM suggesting best parameters | |||||||||
[97] | ✔ | ✔ | Environmental review with cons of additives and pros of dry-EDM | ||||||||||||
[98] | ✔ | ✔ | ✔ | New pulse generator for rough cut and better SR | |||||||||||
2017 | [99] | ✔ | ✔ | ✔ | ✔ | Investigate wire breakage cutting polymeric foams | |||||||||
[100] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Review on processes optimisation by Response Surface | ||||||||
[101] | ✔ | ✔ | ✔ | ✔ | ✔ | Review on processes optimisation | |||||||||
[55] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Dielectric temperature with higher MRR (30%) and better SR | |||||||
[102] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Machining parameters against harmful wire vibration | |||||||
[103] | ✔ | ✔ | ✔ | ✔ | ✔ | New wire mechanism for improved SR and MR in tapper | |||||||||
[1] | ✔ | ✔ | ✔ | ✔ | ✔ | High-speed EDM using air as a dielectric | |||||||||
[104] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | The performance index for high MRR | ||||||||
[48] | ✔ | ✔ | ✔ | ✔ | ✔ | Review on Micro-electrode fabrication processes | |||||||||
[105] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for Udimet-L605 | |||||||||
[13] | ✔ | ✔ | ✔ | ✔ | Investigate fluid behaviour with ultrasonically activated wire | ||||||||||
[74] | ✔ | ✔ | ✔ | ✔ | ✔ | Improved accuracy and MRR with ultrasonically activated wire | |||||||||
[106] | ✔ | ✔ | ✔ | ✔ | A dielectric formulation for higher MRR and energy in HS-WEDM | ||||||||||
[107] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Review on causes of wire electrode wear | ||||||||
[108] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for titanium Ti-6Al-4V | ||||||||
[109] | ✔ | ✔ | ✔ | ✔ | ✔ | Ultrasonic wire and process parameters for different materials | |||||||||
2018 | [62] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for stainless-clad steel | |||||||
[110] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for nano-TiO2 dispersed austenite steel | |||||||||
[111] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for H21 tool steel | |||||||||
[112] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | New HS-WEDM with long wire with process parametrisation | |||||||
[113] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for Indian RAFM steel | |||||||||
[5] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for Pure Titanium | |||||||||
[114] | ✔ | ✔ | ✔ | ✔ | ✔ | Process optimisation for Inconel 825 | |||||||||
[33] | ✔ | ✔ | ✔ | ✔ | ✔ | Review on processes optimisation for titanium and its alloys | |||||||||
[115] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Review on processes optimisation for Metal Matrix Composites | |||||||
[116] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for NiTi Superelastic Alloy | |||||||||
[117] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Inconel 718 | |||||||||
[118] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for high-speed steel (HSS) M2 | |||||||||
[119] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Titanium Grade 6 | ||||||
[120] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Ni-Ti shape memory alloy | |||||||||
[121] | ✔ | ✔ | ✔ | ✔ | Influence of cut direction in SR | ||||||||||
[122] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for angular error in taper cutting | |||||||||
[123] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Ti50Ni48Co2 Shape Memory Alloy | |||||||||
[124] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for AA 7075 Aluminium Alloy | |||||||||
[125] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for cladded material | |||||||||
[14] | ✔ | ✔ | ✔ | ✔ | Review of new materials for sinking EDM electrodes | ||||||||||
[126] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Maraging steel | |||||||||
[127] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Ti-6Al-4V alloy | |||||||||
[128] | ✔ | ✔ | ✔ | ✔ | ✔ | The thickness and servo voltage are the most influencing in a taper cut | |||||||||
[129] | ✔ | ✔ | ✔ | Prediction for consumables and wear parts | |||||||||||
2019 | [130] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for 16MnCr5 Alloy steel | ||||||||
[131] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Magnesium metal matrix composite | |||||||||
[4] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Al (6082)/tungsten carbide composite | ||||||||
[132] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | High-performance wire increasing MRR (~29%) and SR (~10%) | ||||||||
[133] | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Ti–6Al–4V by Artificial Intelligence | ||||||||||
[134] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Ti50Ni49Co1 Shape Memory Alloy | |||||||||
[135] | ✔ | ✔ | ✔ | ✔ | ✔ | Processes optimisation for Al5083/7% | |||||||||
[136] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Review on EDM applications of ultrasonic vibrations | ||||||||
[137] | ✔ | ✔ | Additive manufacture of EDM electrodes delivers design freedom |
Main Targets | Used Means | M.P.T.s | Deliverable | ||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Year | Reference | Improve Accuracy | Mitigate Vibration | Propose Compensation | Mitigate Low Stiffness | Damping Tools | Simulation | Coupling Mechanisms | Control Strategies | Methods | Processes | Tools | |
2006 | [149] | ✔ | ✔ | ✔ | ✔ | ✔ | Damping tool | ||||||
2007 | [150] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Damping attenuation | |||
2009 | [151] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Real-time compensation | ||||
2010 | [152] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Tool displacement simulation | |||||
[153] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Dynamic compensation | ||||||
2011 | [154] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Literature review IR machining | |||
2012 | [155] | ✔ | ✔ | ✔ | Wire cutting process with design freedom | ||||||||
[156] | ✔ | ✔ | ✔ | ✔ | Automated robotic deburring | ||||||||
[157] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Real-time control | ||||||
2013 | [158] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Literature review on IR as a CNC-like machine | |||
[159] | ✔ | ✔ | ✔ | ✔ | ✔ | Contact sensing-based for grinding process | |||||||
[160] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | CNC-like machining | ||||||
[21] | ✔ | ✔ | ✔ | ✔ | Multi-process programming | ||||||||
[161] | ✔ | ✔ | ✔ | ✔ | Offline programming | ||||||||
[162] | ✔ | ✔ | ✔ | ✔ | Wire cutting process | ||||||||
[25] | ✔ | ✔ | ✔ | ✔ | ✔ | Automated robotic deburring | |||||||
[26] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Map main sources of IR machining error | ||||
[22] | ✔ | ✔ | ✔ | ✔ | Improved deburring process | ||||||||
[163] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Dynamic compensation by piezo actuators | ||||||
2014 | [164] | ✔ | ✔ | ✔ | ✔ | ✔ | Robot stiffness | ||||||
[165] | ✔ | ✔ | ✔ | Image-based print process path | |||||||||
2015 | [166] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Literature review IR machining | |
[167] | ✔ | ✔ | ✔ | Automatic tool changing system | |||||||||
[168] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Literature review IR machining | |||
[16] | ✔ | ✔ | ✔ | ✔ | ✔ | Polish end-effector | |||||||
2016 | [169] | ✔ | ✔ | ✔ | ✔ | ✔ | CNC-like machining | ||||||
2017 | [170] | ✔ | ✔ | ✔ | ✔ | ✔ | Robot stiffness | ||||||
[171] | ✔ | ✔ | ✔ | Wire cutting process | |||||||||
[172] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Polishing | ||||||
[148] | ✔ | ✔ | ✔ | ✔ | ✔ | Robot stiffness | |||||||
[173] | ✔ | ✔ | ✔ | ✔ | ✔ | Trajectory (cutting path) for the grinding process | |||||||
[174] | ✔ | ✔ | ✔ | A mathematical model for plasma coating | |||||||||
2018 | [175] | ✔ | ✔ | ✔ | 3D vision | ||||||||
[176] | ✔ | ✔ | ✔ | ✔ | Geometric design freedom | ||||||||
[177] | ✔ | ✔ | ✔ | 3D workpiece into wire cutting program | |||||||||
[178] | ✔ | ✔ | ✔ | ✔ | ✔ | Robot stiffness | |||||||
[179] | Coupling mechanisms | ||||||||||||
2019 | [180] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Contact sensing-based for grinding process | ||||
[181] | ✔ | ✔ | ✔ | ✔ | ✔ | Real-time control | |||||||
[23] | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | Literature review IR machining | |||
[182] | ✔ | ✔ | ✔ | Wire cutting process |
Six-Axis Robots Characteristics | Die sink EDM | Micro EDM | Milling EDM | Wire EDM | |
---|---|---|---|---|---|
(−) | Low stiffness under force or vibrations | 1 | 1 | 1 | 1 |
(−) | Limited accuracy | 0 | 0 | 0 | 0 |
(−) | Limited end-effector weight | 0 | 1 | 0 | 1 |
(−) | Limited sealing against fluids | 0 | 0 | 1 | 1 |
+ | Provides a large working envelope | 0 | 0 | 1 | 1 |
+ | Able to work for many hours | 1 | 0 | 1 | 1 |
+ | Can offer increased design freedom | 1 | 0 | 1 | 1 |
+ | Offer complex cutting path programming | 1 | 1 | 1 | 1 |
+ | Offer several options for process sensing and control | 0 | 1 | 1 | 1 |
Best alignment | 4 | 4 | 7 | 8 |
SWOT scenarios | Wire EDM in CNC Machines | (+) Desirable | |||
Strengths | Weaknesses | ||||
+WE S1. High accuracy | (−)WE W1. Low MRR | ||||
+WE S2. High SR quality | (−)WE W2. Low design freedom | ||||
+WE S3. Ability to cut hard materials | (−)WE W3. Limited envelope | ||||
+WE S4. No vibration or forces | (−)WE W4. Expensive wire usage | ||||
Machining Robots | Strengths | +IR S1. Large envelope | Scenario #1 Strengths combinations | Scenario #2 WEDM’s Weaknesses & IR’s Strengths | Undesirable |
+IR S2. Design freedom | |||||
+IR S3. Path programming | |||||
+IR S4. Easier sensing | |||||
Weaknesses | (−) IR W1. Low stiffness | Scenario #3 IR’s Weaknesses & WEDM’s Strengths | Scenario #4 Weaknesses combinations | ||
(−) IR W2. Low accuracy | |||||
(−) IR W3. Unable to cut hard materials | |||||
(−) IR W4. Limited EE weight | |||||
(+) Desirable | Undesirable | (−) |
SWOT Scenarios Groups | W.E.D.M. | IR | Plausibility Results | |||
---|---|---|---|---|---|---|
−WEDM | +WEDM | −IR | +IR | |||
WEDM | (−)WEDM Weaknesses | 1.00 | 0.69 | 1.44 | 0.41 | 18.1% |
+WEDM Strengths | 1.44 | 1.00 | 2.08 | 0.48 | 25.0% | |
IR | (−)IR Weaknesses | 0.69 | 0.48 | 1.00 | 0.41 | 13.9% |
+IR Strengths | 2.47 | 2.08 | 2.47 | 1.00 | 43.1% | |
Consistency Ratio | 1.1% |
No. | Problem or Component | TRIZ Problem Modelling | TRIZ Principle | Conceptual Solution | |||
---|---|---|---|---|---|---|---|
Technical Contradiction | Physical Contradiction | Trend of Evolution | |||||
1 | Wire erosion in HS-WEDM | Provide intense and prolonged erosion on the workpiece without being eroded | - | - | - Regeneration | Add a process able to regenerate and compensate for the wire erosion. Here, a light wire drawing may accommodate raised edges and pits, thus prolonging the wire life | |
2 | In HS-WEDM, wire erosion creates sharp edges and pits on the surface | - | - | - Regeneration- Universalisation | Use a conductive graphite brush to compensate for erosion and connected directly to the pulley and in contact with the wire | ||
3 | Dielectric flushing efficiency | It needs to go deep into the kerf but get out fast | - | - | - Mechanical vibration | Use ultrasonic wire activation to improve fluid atomisation from a spray nozzle | [74] |
4 | Wire short circuit | It needs to be a large wire to cut more extensive parts but a short wire to avoid bending | Use stationary wave on the wire to stabilise and overcome wire bending by attraction to the workpiece | ||||
5 | Waste of time due to wire short circuit | Needs to move away from to workpiece and back with nearly no time | - | - | Adopt piezo actuator able to move with high frequency as well as in microscale | ||
6 | Control in wire tension | It needs to provide tensioning currently by a gravity field, but in any direction | - | - | - Replace a mechanical system | Use ferromagnetic powder, which apparent viscosity, to create an attached magnetic field controlled by the coil current | |
7 | The wire running out of the pulley | Need to be fixed to align the wire but mobile to accommodate disturbances | - | - | - Universalisation | The wire drives itself by self-centred bearings with integrated double V groove | |
8 | Wire composition | Need different combined materials in complex shapes yet less complexity | - | - Increasing segmentation | - Object segmentation | Use mature technology from the electric or lifting industry to compose complex combinations of segmented wire materials and functions | |
9 | The high weight of End-Effector | It needs to be stiff but light | - Ticker and yet light components | - | - Porous materials | Adopt topologic optimisation and lattice structure made of 3D print | |
10 | Surface burning in HS-WEDM | Use all wire extension with no change in the rotation direction | - | - Increasing Dynamism | - Evolve from solid to jointed system | The wire has its ends precisely attached, allowing it to run continuously in the same direction | |
11 | - | - | - Thinking in Time and Scale- The wire reciprocates by the supersystem | The robot detects the end of the wire, stop, move out, revolve the 6th axis end-effector in 180° and restart cutting in the same direction | |||
12 | Low SR with high MRR | It needs a high energy pulse for more MRR and less for better SR | - | - | - Thinking in Time and Scale to Separate in Time | Pulse generator with higher frequency removes more material per time unity with lower energy resulting in better SR keeping high MRR [188] | |
13 | Difficult to flush in tilt positions due to gravity (Phenomenon of unilateral water curtain) | Wire move to taper angles while dielectric flows in the vertical direction | - Flow against gravity | - | - Blessing in disguise (harm to benefit) | Robot cuts with wire in a constant optimum diagonal angle X°, and always top to bottom, thus gravity assures flooding and flushing the kerf |
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Almeida, S.T.; Mo, J.; Bil, C.; Ding, S.; Wang, X. Conceptual Design of a High-Speed Wire EDM Robotic End-Effector Based on a Systematic Review Followed by TRIZ. Machines 2021, 9, 132. https://doi.org/10.3390/machines9070132
Almeida ST, Mo J, Bil C, Ding S, Wang X. Conceptual Design of a High-Speed Wire EDM Robotic End-Effector Based on a Systematic Review Followed by TRIZ. Machines. 2021; 9(7):132. https://doi.org/10.3390/machines9070132
Chicago/Turabian StyleAlmeida, Sergio Tadeu, John Mo, Cees Bil, Songlin Ding, and Xiangzhi Wang. 2021. "Conceptual Design of a High-Speed Wire EDM Robotic End-Effector Based on a Systematic Review Followed by TRIZ" Machines 9, no. 7: 132. https://doi.org/10.3390/machines9070132