In transformers with epoxy resin insulation structures, the formula curve is commonly employed in the focusing mechanisms of optical instruments. As technology advances, there is an increasing demand for higher accuracy and better surface quality of these curves. To address this, a novel approach for machining high-precision curves on wire-cutting dies has been proposed, focusing on enhancing both machining accuracy and efficiency while comparing it with conventional methods.
The part in question is a dial component made from Cr12MoV steel, known for its excellent hardenability, hot hardness, and moderate toughness. The roughness requirement for all sides of the curve is Ra = 1.6 μm, and the final product must be free of deformities or distortions after processing.
Traditional processing methods involve plotting a series of discrete points along the curve and inputting their coordinates into a computer for programming. However, this method reduces the accuracy of the cut as fewer discrete points are used, leading to poor surface quality that does not meet modern standards.
To improve upon this, the latest version of CAXA software was utilized to design and program the curve. This involved establishing the curve equation and creating a corresponding data file. Despite having a formula curve editing function, CAXA’s instructions did not clearly outline the input process, resulting in errors when following standard procedures. After extensive experimentation, the correct formulas were identified:
Ï = 16.5 - 4.1tan(t/2)sin(60° + t/3) (0° ≤ t ≤ 21.7°)
Ï = 16.5 - 4.1tan(1.25t - 16.275)sin(60° + t/3) (21.7° ≤ t ≤ 30°)
23² = (x + 1.2377)² + (y + 10.5667)² (30° ≤ t ≤ 90°)
Next, the graphical representation of the curve was created through the "Formula Curve" menu. For data input, since the line-cutting V2 version could not directly use the machine tool's programming functions due to software limitations, the .IGS data interface file format was adopted to bridge the gap between the two programs. First, the graphic was drawn in V2, saved as an .IGS file, and then imported into the programming software for further processing.
When programming, attention was paid to minimizing data loss during the .IGS import and ensuring that the "curve precision" setting was adjusted to its lowest value to generate a smoother curve with more points.
By employing this advanced method, the precision and surface roughness of the machined curve met the stringent requirements of the part, showcasing a significant improvement over traditional techniques. This approach not only enhances the quality of the final product but also demonstrates the potential for broader application in similar manufacturing scenarios.
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