Converting a CNC milling machine to a CNC wire saw

1. A system for converting a CNC milling machine to a CNC wire saw machine, the CNC milling machine comprising:

a worktable configured to support a workpiece on a top surface of the worktable;

a first gantry mounted over the worktable, the first gantry configured to be slidable along a first axis relative to the worktable; and

a first carriage mounted on a transversely disposed section of the first gantry, the first carriage configured to be slidable on the transversely disposed section of the first gantry along a second axis relative to the worktable, the second axis perpendicular to the first axis;

a spindle mounted on and moveable with the first carriage, and

wherein the system comprises:

a second gantry configured to be coupled and moveable with the first gantry along the first axis, the second gantry comprising;

a pair of parallel elongated support legs, each elongated support leg of the pair of parallel elongated support legs positioned on a respective side of the worktable; and

an upper transverse beam laid across upper ends of the pair of parallel elongated support legs along the second axis;

a second carriage slidably mounted on the upper transverse beam, the second carriage configured to be coupled with the first carriage, the second carriage further configured to be moveable with the first carriage along the second axis;

a gearbox disposed within and moveable with the second carriage, the gearbox configured to be coupled with the spindle;

a drive pulley coupled with the spindle via the gearbox, the gear box further configured to transfer a rotational movement of the spindle to the drive pulley;

a plurality of idler pulleys mounted on the second gantry, the plurality of idler pulleys rotatable on a plane of rotation perpendicular to a plane of rotation of the spindle; and

a wire tension mechanism, comprising:

an extension leg attached to or integrally formed with a first elongated support leg of the pair of parallel elongated support legs, the extension leg extended from the top end of the first elongated support leg along a longitudinal axis of the first elongated support leg;

a curved guide rail, a first end of the curved guide rail attached to or integrally formed with a top end of the extension leg, a second opposing end of the curved guide rail attached to or integrally formed with the top end of a second elongated support leg of the two elongated support legs, the curved guide rail bent downward on a transverse plane, the transverse plane parallel with the pair of parallel elongated support legs and the upper transverse beam;

a vertical guide rail extended upward along a third axis from a top end of the second carriage, the third axis perpendicular to the second axis;

a first bearing block slidably coupled with the vertical guide rail, the first bearing block moveable along the third axis, the first bearing block further comprising a follower coupled with and moveable along the curved guide rail; and

a top tension wheel mounted on the first bearing block, the top tension wheel rotatable about a rotational axis perpendicular to the upper transverse beam; and

a wire attached to the drive pulley, the plurality of idler pulleys, and the top tension wheel, the drive pulley configured to drive the wire to travel through the drive pulley, the plurality of idler pulleys, and the top tension wheel, in an endless wire loop.

2. The system of claim 1 , wherein the second gantry further comprises:

an upper guide rod mounted on and extended along the upper transverse beam,

wherein the second carriage is slidably coupled with the upper guide rod, the second carriage slidable along a longitudinal axis of the upper transverse beam.

3. The system of claim 2 , wherein the first carriage is coupled with a first drive screw, the first drive screw configured to actuate a translational movement of the first carriage along the second axis.

4. The system of claim 3 , wherein the first gantry is further coupled with a second drive screw, the second drive screw configured to actuate a translational movement of the first gantry along the first axis relative to the worktable, the first axis and the second axis mutually perpendicular with an axis that is normal to the top surface of the worktable.

5. The system of claim 1 , wherein the gearbox comprises:

a bevel gear set coupled between the spindle and the drive pulley, the bevel gear set configured to transfer the rotational movement of the spindle to the drive pulley, a rotational axis of the spindle perpendicular to a rotational axis of the drive pulley.

6. The system of claim 5 , wherein the system further comprises:

a lower transverse beam connected to and transversely extended between the pair of parallel elongated support legs, the lower transverse beam extended along the second axis and parallel with the upper transverse beam;

an open linear bearing comprising a lower linear guide rod mounted on and extended along the lower transverse beam, the open linear bearing further comprising a lower linear bearing block slidably coupled with the lower linear guide rod, the lower linear bearing block slidable along a longitudinal axis of the lower transverse beam;

a lower tension wheel mounted on the lower linear bearing block, a rotational axis of the lower tension wheel parallel with the first axis, the lower tension wheel vertically aligned with the drive pulley along an axis parallel with the pair of parallel elongated support legs, the lower tension wheel rotatable on a plane of rotation of the drive pulley.

7. The system of claim 6 , wherein a cutting portion of the endless wire loop comprises a segment of the wire linearly stretched between the drive pulley and the lower tension wheel.

8. The system of claim 7 , wherein the plurality of idler pulleys comprise a lower idler pulley mounted on a first elongated support leg of the pair of parallel elongated support legs, the lower idler pulley horizontally aligned with the lower tension wheel along the second axis, the lower idler pulley rotatable on a rotational plane of the lower tension wheel.

9. The system of claim 8 , wherein the plurality of idler pulleys further comprise an upper idler pulley mounted on the first elongated support leg of the pair of parallel elongated support legs, the upper idler pulley vertically spaced apart from the lower idler pulley along a longitudinal axis of the first elongated support leg, the upper idler pulley rotatable on a rotational plane of the lower idler pulley.

10. The system of claim 6 , wherein the worktable further comprises:

a first plurality of longitudinal grooves on the top surface of the worktable extended along the first axis; and

a plurality of guide rods, each guide rod of the plurality of guide rods disposed within a corresponding longitudinal groove of the first plurality of longitudinal grooves,

wherein the lower transverse beam further comprises a second plurality of grooves on a lower surface of the lower transverse beam, the lower surface of the lower transverse beam facing the top surface of the worktable, each groove of the second plurality of grooves coupled with a corresponding guide rod of the plurality of guide rods.

11. The system of claim 1 , wherein the follower comprises a rotatable wheel connected to a first side of the first bearing block via a first connecting rod, the rotatable wheel rotatable about a rotational axis parallel with the first axis.

12. The system of claim 11 , wherein the top tension wheel mounted on a second side of the first bearing block via a second connecting rod, the second side opposite the first side, the second connecting rod parallel with the first connecting rod.

13. The system of claim 1 , wherein the extension leg and the upper transverse beam are of the same length.

14. The system of claim 13 , wherein a vertical distance between a given point on the curved guide rail and a corresponding point on the upper transverse beam may be defined by:

wherein,

z

=

2

⁢

k

⁢

x

x

+

k

z denotes the vertical distance between the given point on the curved guide rail and the corresponding point on the upper transverse beam,

x denotes a horizontal distance between the given point on curved guide rail and the second end of the curved guide rail along the second axis, and

k denotes the length of the upper transverse beam.