Wire-cut electric discharge machine

Abstract: A wire-cut electric discharge machine is described in which machining is carried out in a gap constructed by wire electrode and workpiece. The wire-cut electric discharge machine controls the mean voltage or mean current detected in the detection circuit in response to the variation of the feed rate of the workpiece. The electrostatic attractive force and discharge repulsive force act to the workpiece and make a balance. As a result, the arcuate shape distortion is canceled.

Description: The invention relates to a high precision wire-cut electric discharge machine. More particularly, the invention concerns a wire-cut electric discharge machine for preventing the occurrence of an arcuate shape on a cutting surface of workpiece by controlling the discharge repulsive force and the electrostatic attractive force generated between wire electrode and workpiece so as to have the two forces cancel out each other. In the conventional wire-cut electric discharge machine, an arcuate shape is generated on the surface of the workpiece during finish machining. The arcuate shape has a degraded working precision. The arcuate shape is a characteristic phenomenon generated in the wire-cut electric discharge machine and also is considered a serious problem. FIG. 9 a shows a concave arcuate shape, and FIG. 9 b shows a convex arcuate shape. The arcuate shape and its volume depends on the working condition and workpiece thickness. The construction and operation of the conventional art machine will be hereinafter described.explained. FIG. 8 shows a construction of the conventional wire-cut electric discharge machine. In FIG. 8, a wire electrode 1 provides one electrode of the electric discharge machine. A workpiece 2 is a material processed by wire-cut electric discharge machine. A wire bobbin 3 provides a wire which is constructed to act as a wire electrode. Upper nozzle 4a and lower nozzle 4b provide dielectric working fluid into a discharge gap. Power supply terminals 5 are in electrical contact with the wire electrode and provide the working voltage and working current that is supplied at the gap. A tension roller 6 gives tension to the wire electrode 1. A wire collecting box 7 collects the wire. A working power source 8 provides current which flows within the discharge gap constructed of the wire electrode 1 and the workpiece 2. A voltage detection circuit 9 detects the mean voltage value at the discharge gap. A control circuit 10 controls the feed rate of the workpiece 2 according to the result of the mean voltage detection circuit 9. A servo amplifier 11 drives a driving motor apparatus 12. A driving motor 12 causes the workpiece 2, mounted on the X-Y cross table (not shown), to be moved in the X and Y directions. The operation of the conventional art will be hereinafter described with reference to FIG. 8. A discharge gap is formed between the workpiece 2 and the wire electrode 1 . The wire electrode 1 runs through the gap under the tension applied by the tension roller 6, and a working current is supplied to the wire electrode 1 from the working power source 8 through power supply terminals 5. Pure water provided as the working fluid is supplied into the discharge gap from upper side and lower side through working fluid nozzle 4a, 4b. The pure water causes the generation of a discharge phenomenon in the gap, between the wire electrode and the grounded workpiece. The voltage detection circuit 9 connected to the discharge electrode 1 and workpiece 2 detects the mean voltage that appears during a machining of the workpiece. The control circuit 10 is responsive to the voltage detection circuit 9 and controls feed rate of the workpiece 2 so that the detected voltage is maintained to be predetermined value. Specifically where there is a higher mean voltage as compared to the predetermined voltage,this shows that there exists a larger discharge gap distance than a predetermined value. Therefore the control circuit 10 controls the servo amplifier 11 so that the driving motor 12 increases the feed rate. When the feed rate is increased the discharge gap distance becomes smaller. Conversely, where there is a lower mean voltage than a predetermined voltage, this shows that there is a smaller discharge gap distance than the predetermined value. Therefore the control circuit 10 controls the servo amplifier 11 so that the driving motor decreases the feed rate. When the feed rate decreases the discharge gap becomes larger. Namely, the control circuit 10 controls the discharge gap to be constant. FIG.11 shows the connection between the discharge voltage wave form and the discharge current wave form. As shown in the figure, high discharge voltage is applied to the gap during on-time t 1 . After the gap insulation breaks down, discharge current flows during t 2 , and then the discharge ceases during off-time t 3 . The period of the discharge voltage T is expressed such as T = t 1 + t 2 + t 3 . In the figure, mean voltage V is a obtained by equalizing the discharge voltage for one or more periods. In general, very precise machining (second cut) is carried out after rough machining (first cut). During the precise machining, arcuate shape error which is a characteristic phenomenon occurring in wire-cut machining, is generated on the surface of the workpiece. FIG.10(a) and 10(b) shows a typical arcuate shape that has been measured on the surface of a workpiece after precise machining. The straight line shows the expected value with no error and the polygonal line shows the result of an actual measurement. From the figures it is understood that the working error is larger at the center of the workpiece. There are many theories in connection to the cause of the arcuate shape . One of the theories states that the working error occurs from the vibration of the wire electrode. Another theory states that the error is generated in response to a resistivity decrement, caused by discharge ionization at the center of the gap, as the working fluid is supplied to the workpiece from the upper side and the lower side. But these two theories do not provide enough information to permit the development of an effective solution for the arcuate shape. On the other hand, regarding to the problem of wire electrode distortion and deterioration of working precision, Japanese patent publication 29513/1991 describes a method which cancels a discharge repulsive force by intentionally generating an electrostatic attractive force and an electromagnetic force between the wire electrode and the workpiece during a rough cut machining operation. But in the above method, a signal compensation circuit is necessary for the wire-cut electric discharge machine in addition to the work power source. As stated above, according to the conventional wire-cut electric discharge machine, there is no effective method to prevent the generation of the arcuate shape during finish machining. Further, the arcuate shape and its volume are changed according to the machining condition and workpiece thickness. Thus , when the workpiece thickness changes during machining, it has been found that the arcuate shape will always occur on the surface of the workpiece. Therefore, it is very difficult to maintain high precise condition for machining in the conventional discharge machine. In the method disclosed in the Japanese patent publication 29513/1991, the distortion of the wire electrode during rough machining was decreased by applying a compensation signal between the upper and lower electrode or between wire electrode and workpiece. But, since the disclosed method could control the electrostatic attractive force and electromagnetic force only toward the increasing direction, it is impossible to decrease the concave arcuate shape generated in the finish machining. (CH 655 885 A5 discloses a wive-cut electric discharge machine including the features a), b) and e) of the attached claims 1,3. Further, in Fig. 2 of this document a control circuit is shown in which depending on an average voltage between the electrodes the feed rate is controlled and depending on the feed rate the machining cycle frequency is changed inversely the to feed rate. By this and by limiting the duration of the on-time of voltage application to the gap to a predetermined length (T 1 in this document), the deformation of the electrode is said to be eliminated. The feed rate is controlled in such a manner that the average voltage is maintained. A current detection means is constituted by a resistor (R 2 in this document) through which the discharge current flows. The object of the present invention is to provide an electric discharge machine and a method by which the deformation of the electrode can be prevented. This object is solved by a machine according to claim 1 and claim 3 and by a method according to claim 9. Further embodiments and inprovement, of the invention are listed in the dependent claims. FIG. 1 is a block diagram of a wire-cut electric discharge machine embodying the present invention. FIG. 2 shows relationship between the mean voltage and the arcuate shape. FIG. 3 explains the discharge attractive force between wire electrode and workpiece. FIG. 4 explains the distortion occurring in the gap. FIG. 5 shows a dynamic characteristics of the some portion of the wire electric discharge machine when the workpiece thickness is changing on the condition of constant mean voltage. FIG. 6 shows a dynamic characteristics of the some portion of the wire electric discharge machine when the workpiece thickness is changing on the condition of constant mean current. FIG. 7 provides an illustration of corner machining. FIG. 8 is a block diagram of a conventional wire-cut electric discharge machine. FIG. 9 shows some examples of arcuate shapes. FIG. 10 shows the actual measurement result of the arcuate shape during machining. FIG. 11 shows the connection between the discharge voltage wave form and the discharge current wave form. FIG. 12 shows the connection between the discharge current wave form and the discharge voltage wave form on the condition of constant mean voltage. FIG. 13 shows the connection between the discharge current wave form and the discharge voltage wave form on the condition of constant mean current . A cause of the arcuate shape during a machining operation is described hereinafter before the embodiment of the present invention is described. As described above, there are two main theories that attempt to explain the generation of the arcuate shape on the working piece. One is the "vibration theory" which suppose that the arcuate shape is generated by the wire electrode vibration, and another is the "resistivity theory" which suppose that the arcuate shape is caused when the resistivity caused by discharge ionization decreases at the center of the gap. But these two theories have some questionable points. For example: (1) Wire vibration theory; (a) According to the actual vibration measurement, under a slow feed rate during the rough machining, low mode vibration occurs in the wire-electrode 1, but in the finish machining the vibration of the wire electrode 1 becomes random and its amplitude is comparatively small. (b) It is difficult to explain the generation process of the convex arcuate shape during finish machining at a comparatively high feed rate . (2) Resistivity theory; (a) The arcuate shape is generated even if kerosene is used as the machining liquid, which has no significant decrease of resistivity . (b) The arcuate shape is generated even if a high frequency alternating current power source is used even though for such power source an electrolytic action is not generated. As described above, the prior theories can not explain the generation of arcuate shape. Studies reported in the Germany Technical Journal VDI - Zeitschrift, 1976, Vol. 118, No. 1 pp 13- 17, have described that there are forces that act on the wire electrode according to (1) electrolytic action, (2) electromagnetic field, (3) spark discharge or (4) dielectric bubble formation, during discharge machining. Further according to the present invention, it is believed that the electrostatic force between wire electrode and workpiece mostly influences the generation of the arcuate shape. The following is the explanation of the theory underlying the method of the present invention. FIG. 2 shows a relationship between the mean voltage and the arcuate shape for three values of current (A,B,C). From FIG. 2, it is apparent that there is a linear relation between the mean voltage V and the arcuate shape volume δ . Especially, according to the line (A) where the mean current I is small, the concave error is proportional to the mean voltage V. It is thought that the volume of concave shape depends on the electrostatic force between wire electrode 1 and workpiece 2 . FIG. 3 explains the discharge attractive force between a wire electrode 1 and a workpiece 2. Using an electric image method, electrostatic attractive force f 1 per unit length in the discharge gap is calculated as follows: f 1 = (1/2) π∈ 0 V 2 / 2(r + e) {log 2[r+e] / r} where, ∈ 0 : dielectric constant, V : discharge voltage between electrodes, r : wire electrode radius, e : discharge gap distance. FIG.4 is a model figure that is used to calculate the distortion δ of the wire electrode in the gap. In general, the distortion δ is calculated on the basis of the outside force f acting on the wire, δ = f h 2 / 8T where, h : workpiece thickness, T : wire tension. The distortion volume δ 1 responsive to the electrostatic attractive force f 1 is calculated by substituting f 1 from equation (1) into the equation (2), and is shown by the dotted line in FIG. 2. Each of the full lines connected along with white circles, black circles, and white squares show the distortion volume δ attained by actual measurements according to the mean current variation. The distortion volume for a small mean current (A) shows value that is nearly equal to the calculated distortion volume (dotted line). According to an increase of the mean current (A→B→C), the full line shifts to the minus direction (to the direction that the concave shape volume decreases). The gradient of the straight lines A,B,C is constant and the same as that for the calculated electrostatic attractive force (dotted line). This means that electrostatic attractive force f 1 and discharge repulsive force f 2 act on the wire in opposite directions. It is understood from FIG. 2 that as the mean current I become larger, the discharge repulsive force f 2 also becomes larger. Accordingly, the electrostatic force f 1 is canceled by the discharge repulsive force f 2 . From the above results, it is thought that the discharge repulsive force f 2 is substantially proportional to the mean current I. Therefore the discharge repulsive force f 2 is expressed as follows: f 2 = k I where k: proportional constant. It is assumed that, during the finish machining, the discharge repulsive force f 2 and the electrostatic force f 1 act on the wire electrode in opposite directions. As a result, the composition of the two forces causes the distortion of the electrode and generates the arcuate shape. An experiment carried out to confirm the above assumption made apparent several facts. First, during machining, an electrostatic force f 1 proportional to the mean voltage V and a discharge repulsive force f 2 proportional to the mean current I act on the wire electrode. The composition of two the forces act on the wire to make the distortion δ and to form the arcuate shape . Thus, if the discharge repulsive force f 2 is controlled to cancel the electrostatic force f 1 , the distortion of the wire and the generation of the arcuate shape can be prevented. This theory is confirmed in practice. FIG. 1 shows a construction of a wire-cut electric discharge machine of the present invention. In FIG. 1, a wire electrode 1 provides one electrode for the electric discharge machining. A workpiece 2 is a material processed by the wire-cut electric discharge machine. A wire bobbin 3 provides a wire which acts as the wire electrode 1. Upper nozzle 4a and lower nozzle 4b provide dielectric working fluid into a discharge gap. A power supply terminals 5 provides working voltage and working current. A tension roller 6 gives tension to the wire electrode 1. A wire collecting box 7 collects the worn wire. A working power source 8 provides current which flows within the discharge gap between the wire electrode 1 and the workpiece 2. A voltage detection circuit 9 detects mean voltage at the discharge gap. A current probe 13 detects current in the discharge gap. A current detection circuit 14 detects the mean current in the discharge gap. A control circuit 10 controls the feed rate of the workpiece 2 in response to the mean voltage detection circuit 9 and the current detection circuit 14. A servo amplifier 11 drives a driving motor 12. A driving motor 12 causes the workpiece 2, which is mounted on the X-Y cross table (not shown) to be moved in the X and Y direction. Next, an operation of the present invention is explained hereinafter. (1) Constant mean voltage control ; The voltage detection circuit 9 connected between the electrodes detects mean voltage V during machining. And the detected voltage is controlled to be equal to the predetermined setting voltage. If the detected mean voltage is larger than the setting voltage, it shows that the discharge gap distance has become larger. Therefore the control circuit 10 controls servo amplifier 11 so that the driving motor 12 increases the feed rate of the workpiece 2. On the contrary, if the detected mean voltage is smaller than the setting voltage, it shows that the discharge gap has become smaller. Therefore the control circuit 10 controls the servo amplifier 11 so that the driving motor 12 decreases the feed rate of the workpiece 2. FIG. 12 shows the connection between the discharge voltage wave form and the discharge current wave form on the condition of a constant mean voltage. As shown in the figure, high discharge voltage is applied to the gap during on-time t 1 . After the gap insulation breaks down, discharge current flows during t 2 , and then the discharge ceases during off-time. t 3 . The period of the discharge voltage T is expressed such as T= t 1 + t 2 + t 3 . In the figure, a mean voltage V is a obtained by equalizing the discharge voltage for one or more periods. There are many well known method to obtain the mean value of the discharge voltage. For example, they are the methods for changing the on-time and off-time ratio, changing the period of the pulse, or changing the amplitude of the pulse. In the figure, the discharge voltage is controlled so that the mean value become constant by changing the pulse period and the ratio of on-time and off-time. It is easily understood that the mean current increases by shortening the period of the discharge voltage. Generally, in accordance with the present invention, the voltage detection circuit 9 may detect a integral value of the discharge voltage, and the control circuit 10 may control the discharge voltage so that the detected integral value becomes equal to the predetermined value. The integral value may be an average, mean, medium or other integrated value. (2) Constant mean current control ; The current detection circuit 14 detects the mean current I during machining. And the detected current is controlled to be equal to the predetermined setting current. If the mean current between the electrodes is smaller than the setting current, it shows that the discharge gap has become larger and discharge generation rate ( discharge frequency) is lowered . On the contrary if the mean current between the discharge electrodes is larger than the setting current, it shows that the discharge gap has become smaller and the discharge generation rate is increased. Therefore the control circuit 10 controls servo amplifier 11 so that the driving motor 12 decreases the feed rate of the workpiece 2. FIG. 13 shows the connection between the discharge current wave form and the discharge voltage wave form on the condition of a constant mean current. As shown in the figure, a high discharge voltage is applied to the gap during on-time t 1 . In the figure, mean current I is obtained by equalizing the discharge current for one or more periods . The discharge current is controlled to be constant by controlling the pulse period to be constant. It is easily understood that the mean voltage increases by lengthening the period of on-time t 1 and shortening the period of off-time t 2 . Generally, in accordance with the present invention, the current detection circuit 14 may detect an integral value of the discharge current, and the control circuit 10 may control the discharge current so that the detected integral value becomes equal to a predetermined value. This integral value may be an average, mean, medium or other integrated value. In general, the initial working condition is selected so as to not generate an arcuate shape on the workpiece. But if the working piece thickness varies during machining, the balance between electrostatic attractive force f 1 and discharge repulsive force f 2 is lost and the wire electrode 1 causes a distortion having an arcuate shape. For example, if the workpiece thickness becomes twice that of the first value, the electrostatic force f 1 per unit length does not change. But the distortion volume d 1 in response to the electrostatic attractive force f 1 becomes four times as shown in the equation (3), because δ 1 is proportional to square of the workpiece thickness h as shown in equation(2), δ 1 =f 1 • (2h) 2 / 8T = 4 f 1 (h) 2 / 8T= 4δ On the other hand if the workpiece thickness is doubled for a constant mean current, the discharge repulsive force f 2 per unit length becomes 1/2. Therefore the distortion volume δ 2 in response to the discharge repulsive force f 2 is calculated from the equation(2), δ 2 = (1/2) f 2 • (2h) 2 / 8T = 2 f 2 (h) 2 / 8T= 2δ Therefore δ 1 =2 δ 2 . At a result, the wire electrode is attracted to the surface of workpiece and the arcuate shape distortion occurs on the workpiece surface. On the contrary, if the workpiece thickness becomes small during machining, the distortion δ1 in response to the electrostatic attractive force f 1 decreases. If discharge repulsive force f 2 becomes larger than the electrostatic attractive force f 1 , the surface of the workpiece become convex shape. The present invention controls mean current I and mean voltage V so that the electrostatic attractive force f 1 and the discharge repulsive force f 2 always maintain a balance. An operation is explained hereinafter when the workpiece thickness varies during the machining of a workpiece at a constant mean voltage. At the condition of controlling the mean voltage V constant, if workpiece thickness varies during machining workpiece, the feed rate varies. As explained above if workpiece thickness is doubled , the feed rate becomes 1/2 under the condition of controlling the mean voltage to be constant. The control circuit 10 detects the variation of workpiece thickness from the feed rate variation and controls work power source 8 which controls the off time of the machining pulse so that the mean current is doubled. Since the total discharge repulsive force Σf 2 is proportional to the mean current, if the mean current is doubled then the total discharge repulsive force Σf 2 is doubled. On the other hand, even if the workpiece thickness is doubled, the discharge repulsive force f 2 per unit length does not change. But the distortion volume d 2 ' is calculated from the equation (2) as follows: δ 2 '=f 2 (2h) 2 /8T = 4 f 2 h 2 /8T = 4 δ On the other hand, distortion volume d1 in response to the electrostatic attractive force f 1 is calculated as shown in the above equation (3) such as; δ 1 =f 1 • (2h) 2 / 8T = 4 f 1 (h) 2 / 8T= 4 δ Therefore δ 1 = δ 2 ' ; the distortion volume Δ - (= δ 1 -δ 2 ) in response to the electrostatic attractive force f 1 and discharge repulsive force f 2 becomes equal and their balance is maintained. Further, the current flowing in the discharge gap is detected by the current probe 13 and the mean current is detected by the current detection circuit 14. The detected mean current I is controlled by changing the off time of the discharge current. FIGs. 5 (a) - 5(g) show dynamic characteristics of some portion of the wire-cut electric discharge machine when the workpiece thickness is varying under the condition of a constant mean voltage. The lateral axis in FIGs. 5 (a) - 5(g) show time lapse. FIG. 5(a) shows thickness variation of the workpiece. FIG. 5(b) shows constant mean voltage . FIG. 5(c) shows feed rate variation; feed rate is controlled so as to be inversely proportional to the workpiece thickness. FIG. 5(d) shows mean current variation; mean current is controlled so as to be proportional to the workpiece thickness. FIG. 5(e) shows variation of wire distortion volume d1 in response to the electrostatic attractive force f 1 ; electrostatic attractive force f 1 is controlled so as to be proportional to the workpiece thickness h. FIG. 5(f) shows variation of wire distortion volume d2 in response to the discharge repulsive force f 2 ; discharge repulsive force f 2 is controlled so as to be proportional to the workpiece thickness h. FIG. 5(g) shows the electrostatic attractive force f1 is canceled by the discharge repulsive force f 2 and then the wire distortion volume Δ - (=δ1-δ2) becomes 0. Next an operation is explained hereinafter when the workpiece thickness varies during machining workpiece under the condition of a constant mean current. At the condition of controlling the mean current I constant, if workpiece thickness varies during machining workpiece, the feed rate varies. As explained above if workpiece thickness becomes twice, feed rate becomes 1/2 at the condition of controlling the mean current constant. The control circuit 10 detects the variation of workpiece thickness from the feed rate variation and controls work power source 8 which controls the off time of the machining pulse so that the mean voltage becomes 1/2. Since the total electrostatic attractive force Σf 1 is proportional to the mean voltage, if the mean voltage becomes 1/2 then the total electrostatic attractive force Σf 1 becomes 1/2. On the other hand as the workpiece thickness is doubled, the distortion volume δ 1 ' becomes; δ 1 '=1/2 f 1 (2h) 2 /8T = 2 f 1 h 2 /8 = 2 δ Therefore δ 1 ' = δ 2 and the distortion volume according to the electrostatic attractive force f 1 and discharge repulsive force f 2 becomes equal and their balance is maintained. Further the mean voltage of discharge gap is detected by the voltage detection detector 9. The detected mean voltage is controlled by changing the off time of the discharge voltage. FIGs. 6 (a) - 6(g) show dynamic characteristics of some portion of the wire-cut electric discharge machine when the workpiece thickness is varying at the condition of constant mean current. The lateral axis in FIGs. 6 (a) - 6(g) show time lapse. FIG. 6(a) shows thickness variation of the workpiece. FIG. 6(b) shows constant mean current. FIG. 6(c) shows feed rate variation; feed rate is controlled so as to be inversely proportional to the workpiece thickness. FIG. 6(d) shows mean current variation; mean current is controlled so as to be proportional to the workpiece thickness. FIG. 6(e) shows the variation of wire distortion volume d 1 according to the electrostatic attractive force ; electrostatic attractive force f 1 is controlled so as to be proportional to the workpiece thickness h. FIG. 6(f) shows the variation of wire distortion volume d 2 according to the discharge repulsive force f 2 ; the discharge repulsive force f 2 is controlled so as to be proportional to the workpiece thickness. FIG. 6(g) shows the electrostatic attractive force and discharge repulsive force is canceled and the wire distortion volume Δ (=δ1 - δ2) becomes 0. As explained above when the workpiece thickness varies, the electrostatic attractive force f 1 and the discharge repulsive force f 2 is canceled by controlling the mean current or mean voltage during the machining. Therefore, the electrostatic attractive force f 1 and the discharge repulsive force f 2 adjust the balance. Therefore the surface of the workpiece always becomes straight and as a result very high precision is attained. Further in the condition of controlling the above mean voltage constant, corner shape precision is considerably improved. Next, an operation regarding to the corner machining of the present invention is explained hereinafter. FIG. 7 (a) shows machining at the outward corner of the workpiece . At the outward corner, the machining surface area becomes small and the feed rate increases. Therefore, in the conventional machining, the outward corner is usually cut down as shown by dotted line. But according to the present invention the machining current decreases and off time is controlled to be longer. Therefore, the outward corner of the workpiece becomes sharp. FIG. 7 (b) shows machining at the inner corner of the workpiece . At the inner corner, the machining surface area becomes small and the feed rate decreases. Therefore, in the conventional machining, the inner corner is usually cut down as shown by dotted line. But according to the present invention the machining current increases and off time is controlled to be shorter. Therefore, the under cut of the inner corner is prevented. In the above embodiments the mean voltage is controlled in proportion to the feed rate or mean current is controlled inversely proportional to the feed rate. But, the control is not restricted to the proportion or inverse proportion. Mean voltage and mean current may be controlled by suitable on-off pulse rate . And further, instead of the current probe shunt, other current detection circuits constructed by using resistance may be employed.

Claims: A wire-cut electric discharge machine in which machining is carried out in a gap defined by wire electrode (1) and workpiece (2), comprising: a) supply electrodes (5) in electrical contact with said wire electrode (1); b) a working power source (8) providing discharge current to said supply electrodes (5); c) a voltage detection means (9) for detecting an integrated voltage value between the wire electrode (1) and the workpiece (2) obtained by equalizing the discharge voltage at the gap for one or more periods T expressed as T = t 1 + t 2 + t 3 , wherein t 1 is the on-time where high discharge voltage is applied to the gap, t 2 is the time in which the discharge current flows and t 3 is the off-time during which discharge ceases; d) a current detection means (13, 14) for detecting an integrated current value of said discharge current obtained by equalizing the discharge current for one or more of said periods T; and e) means (11, 12) for defining a feed rate between said wire electrode (1) and workpiece (2), and f) a control means (Fig. 5, 12; 10) for controlling (Fig. 5a-c) said feed rate defining means (11, 12) for varying, in response to a change in workpiece thickness (Fig. 5a, h), said feed rate (Fig. 5c) so that said detected integrated voltage value is maintained to be a predetermined value (Fig. 5b, V), and controlling said integrated current value detected by said current detection means (13, 14) so as to increase or decrease (Fig. 5d) the value thereof, in response to said variation of feed rate of the workpiece, such that the electrostatic attractive force (f 1 ) and the discharge repulsive force (f 2 ) at the gap is maintained at substantially equal but opposite values. A wire-cut electrode discharge machine of claim 1, wherein said control means (10) controls said integrated current value detected by said current detection means (13, 14) so as to be inversely proportional (Fig. 5c, Fig. 5d) to the variation of the feed rate of the workpiece (2). A wire-cut electric discharge machine in which machining is carried out in a gap defined by wire electrode (1) and workpiece (2), comprising: a) supply electrodes (5) in electrical contact with said wire electrode (1); b) a working power source (8) providing discharge current to said supply electrodes (5) ; c) a voltage detection means (9) for detecting an integrated voltage value between the wire electrode (1) and the workpiece (2) obtained by equalizing the discharge voltage at the gap for one or more periods T expressed as T = t 1 + t 2 + t 3 , wherein t 1 is the on-time where high discharge voltage is applied to the gap, t 2 is the time in which the discharge current flows and t 3 is the off-time during which discharge ceases; d) a current detection means (13, 14) for detecting an integrated current value of said discharge current obtained by equalizing the discharge current for one or more of said periods T; and e) means (11, 12) for defining a feed rate between said wire electrode (1) and workpiece (2), and f) a control means (Fig. 6, 13; 10) for controlling (Fig. 6a-c) said feed rate defining means (11, 12) for varying, in response to a change in workpiece thickness Fig. 6a; h), said feed rate (Fig. 6c) so that said detected integrated current value is maintained to be a predetermined value (Fig. 6b; I), and controlling (Fig. 6d) said integrated voltage value detected by said voltage detection means (9) so as to increase or decrease (Fig. 6d) the value thereof, in response to said variation of feed rate of the workpiece, such that the electrostatic attractive force (f 1 ) and the discharge repulsive force (f 2 ) at the gap is maintained at substantially equal but opposite values. A wire-cut electrode discharge machine of claim 1 or 3, wherein said control means (10) controls said integrated voltage value detected in said voltage detection means (9) so as to be proportional (Fig. 6) to the variation of the feed rate of the workpiece (2). A wire-cut electrode discharge machine of claims 1 or 3, wherein said integrated value is one of an average, median or mean value. A wire-cut electrode discharge machine of claims 1 or 3, wherein said integrated values are mean values. A wire-cut electrode discharge machine of claims 1 or 3, wherein said control means (10) is operative to change (Fig. 12; Fig. 13) at least the pulse period (T) of the signal being integrated. A wire-cut electrode discharge machine of claims 1 or 3, wherein said control means is operative to change (Fig. 12, 13) the on-off pulse rate of the signal being integrated. A method of machining a workpiece using a wire-cut electric discharge machine having a power source (8) for providing a discharge current to a wire electrode (1) and enabling a discharge across a gap defined by the electrode (1) and workpiece (2), as well as means (10, 11, 12) for defining a feed rate between said wire electrode (1) and workpiece (2), comprising the steps of: a) detecting an integrated voltage value between the wire electrode (1) and the workpiece (2) obtained by equalizing the discharge voltage at the gap for one or more periods T expressed as T = t 1 + t 2 + t 3 , wherein t 1 is the on-time where high discharge voltage is applied to the gap, t 2 is the time in which the discharge current flows and t 3 is the off-time during which discharge ceases, and an integrated current value of said discharge current obtained by equalizing the discharge current for one or more of said periods T; and b) controlling in response to a change of workpiece thickness (Fig. 5a, 6a; h) to vary said feed rate (Fig. 5c, 6c) such that said integrated discharge voltage value (V) or said integrated discharge current value (I) is maintained to be a predetermined value (V or I; Fig. 5b, 6b); and c) controlling (Fig. 12, 13) said detected integrated current value (Fig. 5d, I) or said detected integrated voltage (Fig. 6d, V) value, so as to increase or decrease a respective value thereof, in response to said variation of feed rate of the workpiece such that the electrostatic attractive force (f 1 ) and the discharge repulsive force (f 2 ) at the gap is maintained at substantially equal but opposite values. The method of claim 9, wherein said control is operative by variation of on-off pulse rate. The method of claim 9, wherein said control is in proportion to the thickness (h) of the workpiece. The method of claim 9, wherein the off time of the discharge current value is adjusted to control the detected mean discharge current values. The method of claim 9, wherein the off time of the discharge current value is adjusted to control the detected mean discharge voltage values.

Inventors: MAGARA TAKUJI, MAGARA, TAKUJI, MAGARA, TAKUJI, C/O MITSUBISHI DENKI KABUSHIKI K.
Applicants: MITSUBISHI ELECTRIC CORP, MITSUBISHI DENKI KABUSHIKI KAISHA
Application year: 1991
Main classification: B23H7
IPC codes: B23H1, B23H7