DEVICE FOR MOUNTING THE ELECTROSPARK MACHINING ELECTRODE

Abstract: An electrospark machining system is provided which includes an electrode forming machine which machines an electrode blank into a shaped electrode having a desired profile, an electrospark machine to which the shaped electrode is attached in order to machine a workpiece, and a reference block which is adapted to be attached to the electrode blank and which has a reference surface which can be commonly attached to the electrode forming machine and to the electrospark machine. A method of shaping a workpiece using this system is also provided.

Description: The present invention relates to a mounting assembly for an electrode to be used with an electrospark machine, comprising a reference block (10) directly attachable to a surface of an electrode blank (20) and having at least one surface which serves as a common reference surface (x, y, z) for an electrode forming machine machining the electrode blank (20) in order to produce a shaped electrode having a predetermined profile, and for an electrospark machine to which said shaped electrode is to be attached in order to machine a workpiece. Electrospark machines (also known as EDM or electrodischarge machines) are presently widely used, e.g., to manufacture high precision molding dies for injection molding machines; these electrospark machines are used because of their high machining efficiency. In these systems, the shape of a shaped electrode is accurately reproduced on a workpiece to be machined. Generally, a blank from which the electrode is formed is machined by a wire cut electric spark machine, a cutting machine, or other machine tool, in order to provide a shaped electrode having a desired shape. A molding die having a simple profile can be machined, e.g., by a single shaped electrode. However, a molding die having a complex profile cannot be machined by only a single, shaped electrode. Specifically, such a complex molding die can instead only be machined by a composite machining system, using a plurality of shaped electrodes. Generally speaking, the number of shaped electrodes used in a composite machining process can be reduced or decreased if shaped electrodes having three-dimensional complex profiles could be produced and used. However, in practice, an increased plurality of shaped electrodes are needed to produce shaped electrodes having complex three-dimensional profiles, thereby resulting in an apparatus which would be difficult to maintain. During the conventional machining process of a shaped electrode, six faces of a rectangular parallelepipedic electrode blank are ground in order to provide six reference surfaces which are perpendicular to each other. The electrode blanks can be attached to an electrode forming machine, e.g., a wire cut electric spark (hereinafter electrospark) machine, with the assistance of the reference surfaces on the blank. When the electrode blank is subjected to a two- or three-dimensional machining process, the reference surfaces must be changed in order to again attach the blank to the electrode forming machine. In such a conventional machining process, as noted above, it is necessary to adjust the mounting position of the electrode blank, including but not being limited to centering the blank, and/or creating parallelism or perpendicularity between the reference surface or surfaces and the surface being machined at each change of direction during the machining process. The operations needed to make such adjustments are difficult and troublesome. Accordingly, it is practically impossible to obtain a shaped electrode having a three-dimensional complex profile using conventional methods. Accordingly, during an actual machining process, the molding dies are machined by a composite machining device in which a large number of shaped electrodes having simple profiles are used. The above-noted problems also occur during a machining process using an electrospark machine having a shaped electrode attached thereto. Specifically, when the shaped electrode is transferred from the electrode forming machine to the electrospark machine, unless the positional relationship of the electrode with respect to the electrode forming machine is exactly reproduced between the electrode and the electrospark machine, precise and exact machining by the electrospark machine cannot be achieved. In conventional processes, it is extremely difficult to exactly reproduce the identical positional relationship that the electrode had with respect to the electro forming machine when the electrode is positioned in the electrodespark machine; accordingly, the troublesome and difficult adjusting operations as noted above, e.g., the centering operation, must be effected after the electrode is transferred to the electrospark machine. Further, even after such an adjustment is made, an accurate reproduction of the positional relationship between the electrode and the electrode forming machine, on the electrospark machine, cannot be ensured. One type of shaped electrode is used in which the direction of displacement of the electrode during the course of electrospark machining of a workpiece is perpendicular to the direction of machining of the electrode blank. Using this type of shaped electrode, in conventional processes, the shaped electrode is first machined by the electrode forming machine and removed from the electrode forming machine. Thereafter, the shaped electrode is attached to the electrospark machine after the direction of the electrode is changed by 90°. It is, however, difficult to accurately set the electrode again in the electrospark machine. The failure to accurately position the electrode in the electrospark machine results in a failure to accurately reproduce the shape of the shaped electrode on a workpiece being shaped. EP-A-0 147 531 shows a cubic clamping block for clamping an electrode blank having a prismatic or circular section. The clamping block has a clamping chamber for receiving the electrode blank which may be clamped by clamping screws traversing walls of the clamping chamber. The clamping block has a plain mounting surface for an exact positioning of the clamping block to an electrode forming machine or an electrospark machine without detaching the electrode blank or the formed electrode. In view of only a single mounting or reference surface the degree of freedom for positioning the clamping block is limited. Further the clamping block is restricted to a certain shape of electrode blanks. DE-A-3 005 639 shows a clamping block for clamping rodlike electrode blanks which clamping block has three reference surfaces being perpendicular to each other. The clamping block may be attached to a toolshaft in all possible directions, the toolshaft having also a reference surface. Since the clamping block is fixed to the toolshaft by a screw it can turn around the screw axis. Therefore exact positioning is still cumbersome. The clamping block may also be attached to the toolshaft by means of an adapter having a first groove for receiving a corresponding portion of the toolshaft, and having a second groove for receiving the clamping block in only one predetermined position. An object of the invention is to provide a mounting assembly of the above mentioned kind which is simple and by which an electrode blank and the shaped electrode may be attached to an electrode forming machine and an electrospark machine, respectively, in three dimensions in an easy and exact manner. This problem is solved by a mounting assembly according to claim 1. With such an arrangement, in accordance with the present invention, the three-dimensional positions of an electrode can be definitely and precisely determined by a reference block having three reference surfaces which are normal to each other; and, accordingly, it is possible to machine an electrode having a complex three-dimensional profile. Such an electrode can be formed without any need for performing any adjusting operation, e.g., there is no need to adjust for surface parallelism, perpendicularity or for centering. Such an adjusting operation would otherwise (normally) need to be performed when the direction of machining of the electrode is changed by the electrode forming machine. As a result, no positional adjustments are necessary in accordance with the present invention, either when electrode machining operations occur in different directions, or when the electrode is positioned in an electrospark machine. Further, because no centering operations need be performed during a complex machining operation in which a plurality of shaped electrodes are used, molding dies having complex profiles can be machined with high precision, thereby resulting in the increased applicability of the electrospark machining system and method. Further, in accordance with the present invention, because three-dimensional machining of an electrode can be effected, the number of shaped electrodes needed to produce a large number of identical molding dies can be decreased, thereby resulting in decreased costs for maintaining the shaped electrodes. The reference block which is used can be, e.g., a rectangular block; and holders used in the machinery have reference grooves which are complementary in shape to the shape of the reference block. In another example, both the holder grooves and the block itself, can be substantially V-shaped. Each of the holders may include at least two planar surfaces which are perpendicular to each other, one of the planar surfaces being provided with two intersecting grooves and the other of the planar surfaces including at least one groove. The intersecting grooves of the forming machine holder may comprise means for detachably engaging the reference block insertion portion, and the at least one groove comprises means for detachably engaging an electrode forming tool. The system can also include an electrode forming tool attached to a work table of the electrospark machine, the electrospark machine holder being adjustably supported on the electrode forming tool. The electrospark machine holder includes a substantially vertical guide rail which is slidably engaged by the at least one groove. Each of the holders includes a shaft for respectively mounting the holders to the electrode forming machine and to the electrospark machine. The shafts are substantially cylindrical, and each includes an outwardly extending, rotation restricting pin thereon. Each of the holders includes an integrally attached mounting shaft which comprises means for mounting the holders on the electrode forming machine and on the electrospark machine, respectively; and each of the holder reference grooves is substantially perpendicular to the mounting shaft. Each of the holders includes a reference surface which comprises means for mounting the holders, respectively, to the electrode forming machine and to the electrospark machine; the holder reference surfaces are alternately spaced from, and attached to, the at least one reference groove, by a connecting shaft portion. The reference block and each of the holders can include a plurality of positioning holes and a plurality of positioning pins adapted to be inserted into the positioning holes in order to secure the reference block to the holders. The reference block can include the positioning holes, and the holders include the positioning pins; or the reference block can include the positioning pins and the holders the positioning holes. The reference block includes a blank securing portion adapted to be attached to the electrode blank, the electrode blank securing portion being normal to the reference insertion portion, the reference block thereby being substantially L-shaped. The blank securing portion may also lie in the same plane as the reference insertion portion, wherein the reference block is substantially I-shaped. The electrode forming machine itself can comprise a wire cut electrospark machine. The holder includes two planar surfaces, substantially normal to each other, one of the planar surfaces including two reference grooves which intersect each other, and the other of the planar surfaces including a single reference groove. The holder includes a mounting shaft which comprises a reference surface for mounting the reference block to the electrode forming machine, or the holder includes a mounting surface for mounting the reference block to the electrode forming machine. The holder may be secured to a mounting support, the mounting support having a reference surface which comprises a reference for mounting the holder to the electrode forming machine. The reference block and the holder include a plurality of cooperating positioning holes and pins which are adapted to attach the reference block to the holder. A method of shaping a workpiece in a predetermined configuration by using a mounting assembly according to the present invention comprises mounting an electrode blank to be shaped onto the reference block, attaching the reference block to an electrode forming machine, shaping the blank into a predetermined shape by using the electrode forming machine, detaching the reference block and blank from the holder on the electrode forming machine and attaching the reference block to the holder on an electrospark machine, and shaping a workpiece by using the electrospark machine to which the blank has been attached. The reference block is attached in the same positional relationship to each of the holders. The holder may comprise a substantially parallelepipedic block, the block comprising four side surfaces, an upper surface, and a lower surface, wherein four corner projections extend upwardly from the upper surface, each of the corner projections being spaced from two adjacent corner projections, wherein a plurality of substantially perpendicular grooves are formed between the spaced corner projections, one of the side surfaces including a channel which is adapted to be attached to an electrode forming machine. At least one position limiting member may be attached to a side wall of the reference block and extends upwardly beyond the upper surface of the block. The block has a plurality of bores which are adapted to be aligned with corresponding bores on one surface of the electrode blank, and fastening means adapted to be inserted into the respective bores to connect the reference block to the electrode blank. The electrode blank can be substantially cylindrical, and the reference block can comprise a hollow tube which includes an opening which is adapted to receive one end of the electrode blank. The reference block may be substantially parallelepipedic and includes a central circular opening which comprises means for receiving a projection on a holder which is adapted to be connected to both an electrode forming machine and to an electrospark machine. Alternately, the holder and the reference block include a plurality of aligned bores, with the assembly further comprising a plurality of fastening elements inserted into the bores to attach the holder to the block. A shaft can be attached to the holder, or a mounting member with a reference surface can be attached to the holder. The above and other features and advantages of the present invention will be more fully detailed hereinafter with respect to the attached claims and the accompanying drawings, in which like reference numerals are used to describe similar parts throughout the several views, and wherein: Figs. 1A and 1B are perspective views of a reference block and an electrode blank formed in accordance with the present invention; Fig. 2 is an exploded perspective view of a holder, a reference block, and an electrode blank, positioned on an electrode forming machine (e.g., a wire cutting electrospark machine which is used to form and shape an electrode blank); Figs. 3A and 3B, respectively, are perspective views of two alternate types of holders adapted to be attached to an electrospark machine; Figs. 4A and 4B, respectively, are a perspective view and a side elevational view of a shaped electrode including a holder and a reference block connected to the head of an electrospark machine; Figs. 5A, 5B and 5C, respectively, are perspective, side elevational, and front elevational views of a shaped electrode which is machined from an electrode blank; Figs. 6A, 6B and 6C, respectively, are front elevational views of a reference block illustrated in different mounting positions in order to variously machine the shaped electrode; Fig. 7 is a perspective view of a reference block formed in accordance with an alternate embodiment of the present invention; Figs. 8A and 8B, respectively, are perspective views of two different types of holders which are adapted to be used with the reference blocks illustrated in Figs. 6A-6C; Fig. 9 is an exploded perspective view of another embodiment of a reference block and holder. Referring more specifically to the drawings, Figs. 1A and 1B illustrate a reference block 10 and an electrode blank 20 attached thereto. Normally, different types of electrode blanks 20 in the form of rectangular parallelepipeds are prepared in accordance with the intended shape of the shaped electrode to be formed. In the illustrated embodiments, reference blocks 10A and 10B, of L-shape and I-shape, respectively, are prepared in accordance with the shapes of the portions of the electrode blank which are to be machined. Each of the reference blocks 10A and 10B has at one end a reference insertion portion 13 which includes a butt or end surface (x), a pair of lateral restrictive or defining surfaces (y), which surfaces are spaced a distance (1) from each other, and a pair of longitudinal defining surfaces (z) which are spaced a distance (s) from each other. Surfaces (x), (y) and (z) are reference surfaces which are perpendicular or normal to each other and which are machined and precisely finished, by using a block gauge level, to provide surfaces with a high degree of flatness, and which are accurately and precisely parallel or perpendicular with respect to each other, dependent upon which surfaces are being referred to. In particular, it is important that widths (1) and (s), and most particularly width (s), be accurately formed. Reference insertion portion 13 is provided with an insertion hole 14 into which a setting bolt 101 is adapted to be inserted in order to secure the reference block 10 to a holder 30 (see Fig. 2). Insertion hole 14 is provided with a diameter which is slightly larger than that of the setting bolt such that a slight (but secure) clearance is provided between setting bolt 101 and the interior surface of insertion hole 14. Each of the respective L-shaped and I-shaped reference blocks 10A and 10B is provided with a blank securing portion 15 which is provided with mounting holes 16 to mount on electrode blank 20 (via, e.g., conventional bolts or other fasteners 11) . Blank securing portion 15 of L-shaped reference block 10A is perpendicular to the surface insertion portion 13; on the other hand, blank securing portion 15 of I-shaped reference block 10B is connected to reference insertion portion 13 along the same plane. Mounting holes 16 are provided as either threaded holes or through-holes which are adapted to secure blank 20 to securing portion 15 of reference block 10 via fasteners 11. Electrode blank 20 includes threaded holes (not illustrated) into which conventional setting bolts, e.g. bolts 11, which are also inserted into mounting holes 16 are adapted to be screwed in order to secure a block to the electrode blank. Holders 30 are prepared for use in an electrode forming device, as illustrated in Fig. 2, and for use in an electrospark machine, as shown in Figs. 3 and 4. As illustrated in Fig. 2, each holder 30 is adapted for use in an electrode forming tool 40, i.e., in a wire cut electrospark machine which is widely used as an electrode forming device. Electrode forming tool 40 includes a securing or supporting bed 41 which is adapted to be secured to a work table for a wire cut electrospark machine, and a guide rail or rib 42 which is used to (slidably) adjust the vertical position of holder 30. The direction of travel of the wire of the wire cut electrospark machine is either parallel to guide rail 42 or is inclined at a predetermined inclination angle with respect to guide rail 42. Holder 30 includes a plurality of reference grooves 32, 33 which are formed on a plane which is parallel to guide rail 42. In both Figs. 3 (3A and 3B) and 4 (4A and 4B), holder 30 is secured to a mounting shaft 51, or to mounting member 52, of electrospark machine head 50. There are two types of heads 50, one of which is a shaft type head in which holder 30 is mounted to shaft 51 of the head, as illustrated in Fig. 3B, and the other type being a surface reference type in which holder 30 is mounted to a mounting member 52 with the assistance of a reference surface 53, as illustrated in Fig. 3A. A rotation restricting pin 54 is provided on shaft 51 in order to restrict the angular displacement of the shaft, and to limit the positional relationships in which the holder can be attached to electrospark machine head 50. One electrospark machining process, and an electrode forming process, will now be described herein. Initially, an electrode blank 20 having a profile which corresponds to a desired electrode profile, and either a corresponding L-shaped or I-shaped reference block 10A or 10B, are selected; and mounting holes are formed in the selected electrode blank 20 and the selected reference block 10A or 10B. After these mounting holes are appropriately ground, reference block 10 is secured to electrode blank 20 by setting screws or bolts 11, which are inserted into mounting holes 16, as illustrated in Figs. 1 and 2. The setting screws or bolts are conventional elements. Electrode blank 20, having a reference block 10 secured thereto, is then retained or held by holder 30 of electrode forming tool 40, and is subjected to a wire cut electrospark machining process in order to form the electrode blank into a shaped electrode. During a wire cut electrospark machining process, the insertion surface of reference block 10 is fitted into and secured to one of reference grooves 32, 33 or 34 of the holder, such that reference surface (z) of insertion portion 13 of the reference block will come into close surface contact with the side faces of the reference groove to which it is secured, such that reference surface (x) will come into close surface contact with the bottom of the selected reference groove 32, 33 or 34, and such that reference surface (y) will come into close contact with a position restricting member 36 provided on the outer surface of the holder adjacent the grooves, as best illustrated in Figs. 2-4. When electrode 20 is machined in one dimensional direction, insertion portion 13 of reference block 10 is fitted into one of the reference grooves 32, 33 or 34 to complete a desired machining process. When electrode 20 is machined in two- or three-dimensional directions, insertion portion 13 is positioned within more than one of the reference grooves 32, 33 and 34 in order to complete a desired machining process. Figs. 5A, 5B and 5C illustrate an example of a profile of a shaped electrode to be machined. Figs. 6A, 6B and 6C illustrate the different mounting positions of reference grooves 32, 33 and 34 of mounting holder 30 when the shaped electrode is machined, as illustrated in Figs. 5A, 5B and 5C. Arrows A, B, C and D in Figs. 5 and 6 illustrate the directions of travel of an electrospark machining wire (not shown in the drawings but known in the art). In accordance with the present invention, therefore, two- or three-dimensional machining can be effected with a high precision, since the positional relationship between electrode blank 20 and reference block 10 is constant and does not change, and because reference block 10 can always be accurately positioned on holder 30 merely by fitting insertion portion 13 of reference block 10 into respective reference grooves 32, 33 and 34 of the holder. Data representing the position of reference grooves 32, 33 and 34 can be included in machining data which will be input into a computer which controls movement of the wire cut electrospark machine for shaping the electrode blank. When a tapering machining process is necessary, the direction of travel of the wire will be inclined at a predetermined inclination angle, and the height of holder 30 will be adjusted by sliding the holder along guide rail 42 of electrode forming tool 40, such that data representing the height of holder 30 from the work table of the electrode forming machine will be similarly input to the computer control in order to optionally and accurately set the taper to be imparted to the electrode blank during the shaping process. The electrode blank which has been machined by the wire cut electrospark machine in order to form a shaped electrode 20 is then subjected to another machining process which need not be effected by the wire cut electrospark machine, e.g., it can be further shaped by a jig borer or by similar machinery if necessary. In such a case, machining data relating to the wire cut machining process can be supplied to the jig borer; it is also possible to measure the shaped electrode at this time. The machined electrode 20 is then mounted to head 50 of the electrospark machine via holder 30, which is secured to mounting shaft 51 or mounting member 52 without removing reference block 10 from electrode 20, as best illustrated in Fig. 4. Holder 30 is identical to the holder 30 which is used in the electrode forming tool 40 of the wire cut electrospark machine used to shape blank 20, and, accordingly, shaped electrode 20, the machining data from which can be input to the electrospark machine, is then attached to the electrospark machine. Specifically, when insertion portion 13 of reference block 10 is fit within any one of reference grooves 32, 33 or 34 of holder 30, in accordance with a predetermined machining direction of the shaped electrode, and when the setting bolts are screwed within mounting holes 16 and threaded holes 35, the electrode blank being machined will be in the same position as when it was in the wire cut electrospark machine used to shape the blank. When the shaped electrode is then set or attached to the electrospark machine (which positioning will be referred to as a "set change" hereinafter), it will not be necessary to adjust the parallel or perpendicular relationship of the surfaces of the electrode, nor the centering of the electrode, with respect to the holder. Further, the machining and measurement data, i.e., data representing the actual profile of the shaped electrode, will be supplied to the control unit for the electrospark machine. Electrospark machining is then effected by bringing head 50 of the machine close to the workpiece to be machined, such that the workpiece will be shaped by the electrode so as to have a profile precisely identical to the profile of the shaped electrode 20. The present invention can be used in a composite machining process in which a plurality of shaped electrodes having different profiles are used. Namely, during such composite machining, it is important to center electrodes 20; and, in accordance with the present invention, centering of a plurality of shaped electrodes can be easily effected in a single operation, without special adjustment. Further, in accordance with the present invention, because a workpiece having a complex profile can be machined by a single shaped electrode, precise molding dies with complex profiles can be machined by a reduced number of shaped electrodes. Figs. 7 and 8 (8A and 8B) disclose an alternate embodiment of a reference block 10C and holder 30', both formed according to the present invention. In this embodiment, the shaped electrode has a simpler profile. Specifically, reference block 10C includes an electrode blank insertion hole or bore 18, which is adapted to receive an electrode blank in the form of a cylindrical rod 21, and a hole 14' into which a setting bolt (not shown) is inserted to attach the block to a holder. Insertion portion 13' of reference block 10C is essentially identical to the insertion portion of the above-described embodiment. Accordingly, elements corresponding to those in the first embodiment have been designated by the same reference numerals of the those in the first embodiment in this second embodiment; with the exception that primes have been added to describe the similar elements in this embodiment. Holder 30', which is common to both the electrode forming machine and to the electrospark machine, includes a single positioning groove 38 into which insertion portion 13' of reference block 10C is adapted to be inserted. Positioning groove 38 is provided at one end with a position-restricting member 36' attached thereto along the exterior surface of the upper portion of the holder. This member is adapted to sit on or above a seating surface 39, as illustrated in Fig. 8A. In a manner similar to the structure of the first embodiment, two types of holders 30' are provided, a shaft reference type holder in which the holder includes a mounting shaft 51' and a rotation restriction pin 54', and a surface reference type holder in which the holder includes a mounting member 52' with a reference surface 53'. In any event, the positional relationship between mounting shaft 51' or reference surface 53', and positioning groove 38, can be predetermined in advance. Electrode blank 21, which is supported by holder 30' via reference block 10C, is thus adapted to be machined into a predetermined shape by an electrode forming machine, in a fashion similar to that of the first embodiment; thereafter, the shaped electrode thus produced from electrode blank 21 is set into an electrospark machine having an identical holder 30', such that the workpiece to be machined can be machined with a high precision by an electrospark machining process. A different reference block and holder can be advantageously used for a relatively large electrode blank 20a; in Fig. 9, reference block 10D includes two positioning holes 61 and 62, and holder 30a includes two positioning pins 63 and 64 which can be inserted into respective positioning holes 61 and 62. Central positioning pin 63 is integrally attached to holder 30a, and circumferential positioning pin 64 can be detachably inserted into a hole in holder 30a which corresponds to positioning hole 62. Alternatively, it is also possible to provide positioning pins on reference block 10D and to provide the corresponding positional or positioning holes on holder 30a, in a manner opposite from (but similar in purpose) to the illustrated embodiment of Fig. 9. In Fig. 9, reference block 10D includes mounting holes 66 into which set bolts or screws 69 are screwed in order to secure reference block 10D to holder 30a. Set bolts 67, which are inserted into corresponding mounting holes 65, are screw-engaged into corresponding threaded holes (not illustrated) of electrode blank 20a in order to secure block 10D to the electrode blank 20. Set bolts 69 are then inserted into bolt inserting holes 68 of holder 30a in order to secure reference block 10D and electrode blank 20a to holder 30a. There are two possible types of holders, e.g., a shaft reference type of holder and surface reference type of holder, similar to those shown in Fig. 8, although these are not expressly shown in Fig. 9. The holders are adapted to be mounted commonly to an electrode forming machine and an electrospark machine, as noted previously. Similar to the embodiments illustrated in Figs. 7 and 8, in the embodiment of Fig. 9, the electrode blank is mounted to the electrode forming machine via a holder, such that the electrode blank will be shaped into a shaped electrode having a predetermined shape; and, thereafter, the shaped electrode is adapted to be mounted to the electrospark machine via a holder which is identical to the holder of the electrode forming machine, where it will be subjected to electrospark machining with a high precision. In an alternative embodiment of the present invention, it is possible to provide a reference block having a V-shaped cross-section. In this alternative embodiment, the reference groove of the holder is also provided with a V-shape, such that the V-shaped groove will provide two reference surfaces which are substantially perpendicular to each other. Alternately, it is also possible to provide a cross-shaped insertion portion on the reference block and a complementary, cross-shaped reference groove(s) on the holder, in order to facilitate engagement between the holder and the block. As noted from the above explanation, the present invention is most advantageous when identical holders are provided on both the electrode forming machine and the electrospark machine. Alternately, the present invention can be applied only to an electrode forming machine to produce a shaped electrode having a predetermined shape. In this alternate embodiment, the specific holder which is adapted to be mounted to the electrospark machine need not be considered.

Claims: Mounting assembly for an electrode to be used with an electrospark machine, comprising a reference block (10) directly attachable to a surface of an electrode blank (20) and having at least one surface which serves as a common reference surface (x, y, z) for an electrode forming machine machining the electrode blank (20) in order to produce a shaped electrode having a predetermined profile, and for an electrospark machine to which said shaped electrode is to be attached in order to machine a workpiece, characterized in that said reference block (10) includes a parallelepipedic insertion section (13) having three reference surfaces (x, y, z) which are perpendicular to each other, and further characterized by at least one holder (30) which is detachably connectable to said electrode forming machine and/or at least one holder (30) which is detachably connectable to said electrospark machine, said holder (30) including three reference grooves (32, 33, 34) for engaging said three reference surfaces (x, y, z) of said insertion portion (13) of said reference block (10) and supporting said reference block (10) in a predetermined position in said machines, said reference grooves (32, 33, 34) being substantially normal to each other. Mounting assembly in accordance with claim 1, characterized in that two of said grooves are normal to each other within a common plane and a third of said grooves is located in a plane perpendicular to said common plane. Mounting assembly in accordance with claim 1 or 2, wherein said intersecting grooves (32, 33) of the holder (30) comprise means for detachably engaging said reference block insertion portion (13), and one groove comprises means for detachably engaging an electrode forming tool (40). Mounting assembly in accordance with claim 3, wherein said holder (30) has means to be adjustably supported on said electrode forming tool (40). Mounting assembly in accordance with claim 4, wherein said holder (30) includes a substantially vertical guide rail (42) which is slidably engaged by said one groove. Mounting assembly in accordance with one of claims 1 to 5, wherein each of said holders (30') includes a shaft (51) for respectively mounting said holders (30') to said electrode forming machine and/or said electrospark machine. Mounting assembly in accordance with claim 6, wherein said shafts (51) are substantially cylindrical, each of said shafts (51) including an outwardly extending, rotation restricting pin (54) thereon. Mounting assembly in accordance with claim 6 or 7, wherein each of said holders (30') includes an integrally attached mounting shaft (51). Mounting assembly in accordance with one of claims 6 to 8, wherein each of said holder reference grooves (32, 33, 34, 38) is substantially perpendicular to said mounting shaft (51). Mounting assembly in accordance with one of claims 6 to 9, wherein each of said holders (30) includes a reference surface (53) which comprises means for mounting said holders, respectively, to said electrode forming machine and said electrospark machine. Mounting assembly in accordance with claim 10, wherein said holder reference surface (53) is spaced from, and attached to, said one reference groove (38), by a connecting shaft portion (52). Mounting assembly in accordance with one of claims 1 to 11, wherein said reference block (10D) and each of said holders (30a) include a plurality of positioning holes (61, 62) and a plurality of positioning pins (63, 64) adapted to be inserted into said positioning holes (61, 62) in order to secure said reference block (10D) to said holders (30a). Mounting assembly in accordance with claim 12, wherein said reference block (10D) includes said positioning holes (61, 62) and said holders include said positioning pins (63, 64). Mounting assembly in accordance with claim 13, wherein said reference block includes said positioning pins and said holders include said positioning holes. Mounting assembly in accordance with one of claims 1 to 14, wherein said reference block (10) includes a blank securing portion (15) adapted to be attached to said electrode blank (20), said electrode blank securing portion (15) being normal to said reference insertion portion (13), said reference block (10) thereby being substantially L-shaped. Mounting assembly in accordance with one of claims 1 to 14, wherein said reference block (10) includes a blank securing portion (15) adapted to be secured to said electrode blank (20), said blank securing portion (15) lying in the same plane as said reference insertion portion (13), wherein said reference block (10) is substantially I-shaped. Mounting assembly according to one of claims 1 to 16, characterized by said holder (30) comprising a substantially parallelepipedic block, said block comprising four side surfaces, an upper surface, and a lower surface, wherein four corner projections extend upwardly from said upper surface, each of said corner projections being spaced from two adjacent corner projections, wherein a plurality of substantially perpendicular grooves (32, 33) are formed between said spaced corner projections, one of said side surfaces including a channel which is adapted to be attached to an electrode forming machine. Mounting assembly in accordance with claim 17, further characterized by at least one position limiting member (36) attached to a side wall of said holder block (30) and extending upwardly beyond said upper surface of said holder block (30). Mounting assembly according to one of claims 1 to 18, said reference block (10) having a plurality of bores (16) which are adapted to be aligned with corresponding bores on one surface of said electrode blank (20), and fastening means adapted to be inserted into said respective bores (16) to contact said reference block (10) to said electrode blank (20). Mounting assembly in accordance with one of claims 1 to 19, wherein said electrode blank (20) is substantially parallelepipedic. Mounting assembly in accordance with one of claims 1 to 18, wherein said electrode blank (21) is substantially cylindrical and said reference block (10C) comprises a hollow tube which includes an opening (18) which is adapted to receive one end of said electrode blank (21). Mounting assembly in accordance with one of claims 1 to 20, wherein said reference block (10D) is substantially parallelepipedic and includes a central circular opening (61) which comprises means for receiving a projection (63) on a holder (30) which is adapted to be connected to both an electrode forming machine and to an electrospark machine. Mounting assembly in accordance with one of claims 1 to 22, wherein said holder (30) and said reference block (10D) include a plurality of aligned bores (66), said assembly further comprising a plurality of fastening elements (69) inserted into said bores (65) to attach said holder (30) to said block (10D).

Inventors: KANEDA, TOSHIO C/O ASAHI KOGAKU KOGYO K.K., KIMURA, HISAO C/O ASAHI KOGAKU KOGYO K.K., UKAJI, SHIROH C/O ASAHI KOGAKU KOGYO K.K., URATA, KENJI C/O ASAHI KOGAKU KOGYO K.K.
Applicants: ASAHI KOGAKU KOGYO KABUSHIKI KAISHA
Application year: 1987
Main classification: B23H1
IPC codes: B23H1, B23H7, B23H11