Method for enhanced accuracy in machining curvilinear profiles on wire-cut electrical discharge machines

• Universal method of increasing the accuracy of manufactured parts.
• Relatively simple implementation of the method of correcting machining errors.
• The method does not require any additional investments (only typical equipment).
• The errors correction process is conducted on the basis of coordinate measurements.
• Implementation of the method allowed for an increase in the machining accuracy.

The present article describes a method for enhanced accuracy in machining components produced on CNC wire-cut electrical discharge machines. In this method, machining programs are generated on the basis of nominal geometric models of the produced objects, developed in CAD/CAM systems. After the initial machining, coordinate measurements are performed. On the basis of these measurement results, the values and distribution of the machining deviations are determined. The obtained information is then used to modify the nominal geometric models of the produced objects and to correct the machining programs. After that, the machining process and measurements are repeated. The method described in the present article was verified using the example of a curvilinear profile, produced with the use of a wire-cut electrical discharge machine.