Solid modeling of 4-axis wire EDM cut geometry

NC verification has been widely used in milling and turning machining, but the implementation of NC verification for wire electrical discharge machine (wire EDM) has received little attention, made difficult by the characteristics of geometry cut by the thin wire. For an NC verification system, the speed and the accuracy of are two of the most critical issues. In this paper, a novel solid modeling method, which utilizes a dual quadtree structure and a boundary representation, is applied to modeling the parts cut by a wire EDM. In this implementation, two extended quadtrees on the top and bottom surfaces of the stock are first created. Special quadtree nodes are introduced into the dual quadtree structure to model the features associated with the almost coincident surfaces left by a thin wire. The region swept by a wire in each move is generated based on the diameter of the wire, spark gap size and the paths. The overall geometry of the part is represented by a boundary representation which is updated by means of efficient Boolean operations of extended quadtrees. The free-falling objects which may damage the machine tool can be detected. Dimensional inspection and feature detection can be made with the solid model representing the machined part. The system has demonstrated very promising speed and accuracy.