Reverse Engineering Algorithm for Cutting of Ruled Geometries by Wire

Abstract

Abrasive wire cutting (AWC) and wire electric discharge machining (WEDM) are efficient and economical processes for the fabrication of precision parts from bulk material. Operating costs and manufacturing lead times are low compared to more general methods such as 5-axis CNC milling, turning, or electro-discharge machining. In this paper, an algorithm based on differential geometry in Euclidean space is proposed for reverse engineering of ruled geometries. The algorithm can determine whether a given geometry is producible by wire cutting, and can also derive the associated wire trajectories. Implementation is demonstrated by producing complex turbine blade geometries on 4-axis wire cutting machines with an overall shape accuracy of 20–40 μm peak-to-valley.