Deflection Optimization In Y Slide Of EDM Machine

Deflection Optimization In Y Slide Of EDM Machine


Requirements

Correlation of CAE Results with Testing Results

Reducing the Z directional Deflection of Y Slide from 0.2 mm to 0.05 mm


Benefits

Precision of Machining with EDM Technique improved

Machine design compatible with IS Norms and Standards

Highest tolerance requirements achieved


Our Solution

Accurate FEA Model Creation with precisely defining contacts and Joints

Concept generation within a boundary of Design Constraints

Optimized design without affecting other functionalities of the Machine

Disengaging Mechanism Design

Disengaging Mechanism Design

Requirements

Replace the Friction plate clutch design with simple and easy to operate mechanism

Increase the Torque Transmission from 22Nm to >50 Nm

To disengage the power transmitted from Chain drive to Rear Shaft

Disconnect power transfer without stopping the machine

Pulling force to be maintained within 25 N


Benefits

Eliminate use of Friction plate clutch

Easy to maintain and Service

Simple and Elegant solution

Improvement in Torque transmission from 22 Nm to >50 Nm

Ergonomically tested and validated design


Our Solution

Root Cause Analysis

Spring design

CAD model of Concepts

New Concept Generation.

Verifying the final concepts By Hand calculations.

Component level Production Drawings

Assembly Drawings

BOM of the Full Mechanism

Weight Optimization Of EDM Machine Table

Weight Optimization Of EDM Machine Table


Requirements

To reduce the weight of work table and ultimately the entire machine in order to reduce the cost of machine.

Maintain the same deflection (up to a max. of 0.13mm) and achieve the target weight, so that accuracy of machine doesn’t deteriorate.


Benefits

Cost saving of 20% on the full machine

Competitive advantage in the market

Increase in market share

Use of Standard cross sections eliminates need of custom designs

Reduction in manufacturing lead time


Our Solution

Product diagnosis and detailed study on cross-sections, thickness, weight of each part.

Static analysis of given design through CAE simulation and identify deflection parameter.

Preparing concepts on optimising the weight by change in design and achieve the target weight with maintaining the current deflection.

Make elegant design concepts.

Designed table should be leak proof.

Manufacturability check

Design of EDM Machine Table

Design of EDM Machine Table


Requirements

To reduce the weight of the work table and ultimately the entire machine in order to reduce the cost of the machine

Maintain the same deflection (up to a max. of 0.13mm) and achieve the target weight, so that the accuracy of the machine doesn’t deteriorate


Our Solution

Product diagnosis and detailed study on cross-sections, thickness, weight of each part

Static analysis of given design through CAE simulation and identifying deflection parameters

Preparing concepts on optimizing the weight by change in design and achieving the target weight with maintaining the current deflection

Make elegant design concepts

Manufacturability check


Benefits

Cost saving of 20% on the full machine

Competitive advantage in the market

Increase in market share

Use of standard cross sections eliminates need of custom designs

New design is safe in loading and lifting as well