Strategic Approach to Develop Solutions for Shaping Complex Workpieces of Exotic Materials

Exotic materials such as hardened steel and tungsten carbide tool steel have unique resistance and properties that make them hard-to-cut. Thus, research to find better ways to process such materials requires an innovative approach and new ideas. Therefore, the present study investigates the design of a novel WDEM combined with robotic machining to overcome limitations of traditional robotic machining. Wire EDM (WEDM) stands out as a non-traditional machining process able to cut complex profiles of hard-to-cut materials, achieving high dimensional accuracy and superior surface finishing. Unfortunately, WEDM is designed in rigid bed-based CNC machines which restrict design freedom in terms of size, shape and features due to machining envelope constraint. On the other hand, traditional machining processes such as drilling and milling using six-axis industrial robots have been investigated and some applications have successfully delivered cost efficiency, improved envelope and high flexibility. However, due to the structure and strength of the robot arm, accuracy, repeatability and finishing are not comparable to CNC machining outcomes. These researches are also restricted by the power of the robot arm holding the machining tool. This paper explores, identifies and selects suitable configurations and define research actions that must be taken to achieve a highly flexible, accurate machining system for exotic materials.