Horizontal wire electrical discharge machining
A system and method provide for a horizontal wire electrical discharge machining apparatus, including a gantry frame positioned above a worktable to support a workpiece, a reciprocating cutting wire spooled to and from a single drum spool through wire guides and an automatic wire tensioner, wherein during operation the reciprocating cutting wire is pulsed with electric current to erode a surface of the workpiece and the worktable supporting a build plate and the workpiece. The machining apparatus also includes a submersion tank containing deionized water to submerge a face of the build plate and a series of pulleys, the wire guides and the automatic wire tensioner arranged to position the reciprocating cutting wire parallel to the face of the build plate and below a surface of the deionized water in the submersion tank.
1 . A horizontal wire electrical discharge machining apparatus, comprising:
a gantry frame positioned above a worktable to support a workpiece;
a reciprocating cutting wire spooled to and from a single drum spool through wire guides and an automatic wire tensioner, wherein during operation the reciprocating cutting wire is pulsed with electric current to erode a surface of the workpiece;
the worktable supporting a build plate and the workpiece, the worktable movable along a single axis when driven by a servo motor;
a submersion tank containing deionized water to submerge a face of the build plate; and
a series of pulleys, the wire guides and the automatic wire tensioner arranged to position the reciprocating cutting wire parallel to the face of the build plate and below a surface of the deionized water in the submersion tank.
2 . The horizontal wire electrical discharge machining apparatus of claim 1 , wherein the reciprocating cutting wire comprises molybdenum wire.
3 . The horizontal wire electrical discharge machining apparatus of claim 1 , wherein the workpiece is manufactured by a 3D metal printing process.
4 . The horizontal wire electrical discharge machining apparatus of claim 3 , wherein the workpiece comprises an electrically conductive material.
5 . The horizontal wire electrical discharge machining apparatus of claim 3 , wherein the electrically conductive material comprises steel alloy.
6 . The horizontal wire electrical discharge machining apparatus of claim 3 , wherein the electrically conductive material comprises aluminum alloy.
7 . The horizontal wire electrical discharge machining apparatus of claim 3 , wherein the electrically conductive material comprises titanium alloy.
8 . The horizontal wire electrical discharge machining apparatus of claim 1 , further comprising one or more servo motors that adjust one or more axes of the worktable to align the reciprocating cutting wire to the face of the build plate.
9 . The horizontal wire electrical discharge machining apparatus of claim 1 , further comprising a support cord attached to the gantry frame, wherein the support cord supports the workpiece during operation of horizontal wire electrical discharge machining apparatus.
10 . The horizontal wire electrical discharge machining apparatus of claim 1 , further comprising a plurality of support cords attached to the gantry frame, wherein the support cords support the workpiece attached to the build plate.
11 . A method for separating a workpiece from a build plate, comprising:
manufacturing, using a 3D printing process, the workpiece, wherein the workpiece is attached to the build plate;
placing the workpiece and the build plate into a horizontal wire electrical discharge machining apparatus, the horizontal wire electrical discharge machining apparatus comprising:
a gantry frame positioned above a worktable to support the workpiece;
a reciprocating cutting wire spooled to and from a single drum spool through wire guides and an automatic wire tensioner, wherein during operation the reciprocating cutting wire is pulsed with electric current to erode a surface of the workpiece;
the worktable supporting the build plate and the workpiece, the worktable movable along a single axis when driven by a servo motor;
a submersion tank containing deionized water to submerge a face of the build plate; and
a series of pulleys, the wire guides and the automatic wire tensioner arranged to position the reciprocating cutting wire parallel to the face of the build plate and below a surface of the deionized water in the submersion tank; and
operating the horizontal wire electrical discharge machining apparatus to separate the workpiece from the build plate.
12 . The method of claim 11 , wherein the reciprocating cutting wire comprises molybdenum wire.
13 . The method of claim 11 , wherein the workpiece comprises a conductive metal alloy.
14 . The method of claim 13 , wherein the conductive metal alloy comprises steel alloy.
15 . The method of claim 13 , wherein the conductive metal alloy comprises aluminum alloy.
16 . The method of claim 13 , wherein the conductive metal alloy comprises titanium alloy.
17 . The method of claim 13 , wherein the conductive metal alloy comprises a 3D printable metal alloy.
18 . The method of claim 11 , further comprising adjusting, by one or more servo motors, one or more axes of the worktable to align the reciprocating cutting wire to the face of the build plate.
19 . The method of claim 11 , wherein the horizontal wire electrical discharge machining apparatus further comprises a support cord attached to the gantry frame, wherein the support cord supports the workpiece during operation of horizontal wire electrical discharge machining apparatus.
20 . The method of claim 11 , wherein the horizontal wire electrical discharge machining apparatus further comprises a plurality of support cords attached to the gantry frame, wherein the support cords support the workpiece attached to the build plate.