Design of a Wire Cut EDM End-Effector with Strict Robotic Constraints

Wire Electric Discharge Machining (WEDM) stands out as a non-contact and nearly force-free machining technique able to cut complex workpieces, delivering dimensional accuracy and superior surface finishing, especially for exotic super-hard materials. On the other hand, machining with six-axis industrial robots (IR) has received much attention due to its notorious advantages over CNC machines to deliver cost efficiency, large envelope, and complex tool kinematics. However, robot machining suffers from severe limitations regarding the tool payload, chatter, repeatability, accuracy error, complex programming and frequently poor surface finishing. This paper investigates the benefits of combining a robot with WEDM to exploit the advantages of both techniques. However, the new system design is not trivial and will involve a transdisciplinary approach and inventive problem solving to design and control a WEDM end-effector. The present study adopts the TRIZ algorithm approach to design a novel WEDM end-effector and define actions to be taken to achieve a flexible and accurate robotic machining system for hard-to-cut materials.