Narrow groove slotted wire cutting jig

**Abstract:** This paper presents a comprehensive analysis of the structure of narrow-slot parts with uniform circumferential distribution. It covers the entire process from the initial design proposal to the production and assembly of the fixture, emphasizing that even under limited conditions, continuous learning, data collection, and mastering the principles of fixture design can lead to the creation of efficient, reliable, and cost-effective fixtures. The study highlights the importance of precise positioning, rational process planning, and practical application in manufacturing complex components. **Keywords:** *circumferential uniform narrow slot*, *clamp*, *rapid positioning* **Foreword:** When the groove width of machined parts is less than or equal to 1 mm, traditional machining methods become inadequate due to the limitations of cutting tools. In such cases, specialized equipment like wire EDM (Electrical Discharge Machining) becomes essential for processing narrow grooves. Additionally, online circular-cutting machines have historically posed challenges in batch production, prompting the development of auxiliary jigs. These jigs have proven effective in improving accuracy and efficiency during the machining of such components. Recently, a company commissioned us to produce a batch of ring-shaped parts featuring a 0.2 mm wide groove, evenly distributed around the circumference. The part dimensions are φ48 mm × 75 mm, made from 45 steel (as shown in Figure 1). Despite the complexity of the task, we achieved excellent results through careful design and implementation. **Figure 1** **Technical Analysis of the Ring:** - High shape accuracy is required. - The perpendicularity between the φ48 hole and the end face must be within 0.02 mm. - The coaxiality of the φ16 and φ27 holes should not exceed 0.025 mm. - The central axis of the 12 slots must align with the main axis within 0.02 mm. - Positioning requirements are strict, with 12 slots alternating between 50 mm and 35 mm lengths, uniformly spaced around the center circle. The machining specifications include a groove width tolerance of ±0.02 mm, surface roughness Ra ≤ 3.2 μm, and precise distribution of the 12 grooves. Achieving these standards requires both accurate workpiece handling and an advanced fixture system. Conventional machining methods, such as manual scribing, often result in errors, leading to waste and inefficiency. Using an indexing head also presents challenges due to machine size limitations and operator skill requirements. To address these issues, we designed a simple yet effective fixture that mimics the function of an indexing head, significantly improving productivity and accuracy. **Fixture Design Principles:** The primary goals of the fixture design were to ensure dimensional accuracy, increase productivity, simplify manufacturing, and reduce costs. The fixture utilizes a spring-loaded ball mechanism for rapid indexing and positioning, allowing for precise rotation of the flange plate. This system ensures consistent and repeatable positioning, crucial for the uniform distribution of the 12 grooves. **Fixture Structure:** The fixture consists of three main components: a riser seat, a flange plate, and a three-jaw chuck. It allows for fast and accurate positioning, ensuring the uniformity of the 12 slots. The design is compatible with the DK7725e WEDM machine table, making it easy to use and efficient. **Figure 2: Assembly Drawing** 1. Chuck 2. Vertical plate base 3. Flange 4. Steel ball 5. Spring 6. Adjusting screw 7. Fastening nut 8. One-way thrust ball bearing 9. Copper sliding sleeve 10. Chuck bolt **Fixture Production and Assembly:** Key components include: - **Chuck**: A K1180 three-jaw self-centering chuck capable of holding various ring-shaped parts. - **Riser Seat**: Made from A3 steel, it provides structural support and ensures precision through milling and grinding. - **Flange**: Fabricated from 45 steel, it includes six evenly spaced positioning holes and a mandrel with tight tolerances. - **Steel Ball**: Used for precise positioning. - **Spring**: Provides adjustable elastic force to maintain contact. - **Adjustment Screw**: Allows fine-tuning of the spring tension. - **Fastening Nut**: Secures the assembly. - **One-way Thrust Ball Bearing**: Enables smooth rotation. - **Copper Sliding Sleeve**: Ensures smooth movement and minimal friction. - **Chuck Bolts**: Secure the chuck to the flange. **Assembly Process:** The fixture is assembled by first machining all components, then assembling the chuck, flange, and sliding sleeve. Proper alignment and directional assembly techniques are used to minimize rotational errors and improve overall accuracy. **Fixture Operation:** 1. Install and adjust the fixture on the machine table, ensuring alignment with the X and Y axes. 2. Mount the workpiece in the chuck using reverse jaws. 3. Use the machine’s automatic centering function to position the first piece. 4. Lock the coordinates after the first cut and continue machining without repositioning. 5. Two processing methods are available: one-by-one and skipping, depending on groove length and distribution. **Processing Path:** - Gradual method: A → B → C → D → E → F - Skipping method: A → C → E; F → B → D **Important Manufacturing Considerations:** - The clearance between the flange mandrel and sliding sleeve must be H7/h6 to allow free rotation. - The steel ball and its housing must have a gap of 0.05–0.1 mm to ensure flexibility. - The positioning holes on the flange must be precisely aligned to avoid misalignment and maintain accuracy. **Results and Benefits:** - The fixture is cost-effective and easy to manufacture, enabling efficient use of existing machinery. - After machining, the groove dimensions met H8 grade specifications, with surface roughness between Ra 1.2–3.2 μm. - Thousands of parts were produced without defects, significantly improving the company’s efficiency and profitability. - Processing speed increased nearly fourfold, reducing operator workload and increasing productivity. **Conclusion:** Fixture design is a critical aspect of modern manufacturing. Through careful planning, technical expertise, and iterative improvement, even complex parts can be produced efficiently and accurately. This project demonstrates how a well-designed fixture can greatly enhance the machining of round or shaft-like components, offering cost savings, improved quality, and high practical value. **References:** 1. *New Principles of Machine Tool Fixture Design* – Mechanical Industry Press, 1997 2. *Mechanical Worker-Cold Working* – Institute of Mechanical Industry Information, 2003

Coated Steel Wire Rope

- PVC coated Stainless Steel Wire Rope: This type of wire rope is coated with a layer of PVC (polyvinyl chloride) material, which provides protection against corrosion, abrasion, and weathering. It is commonly used in outdoor applications, such as marine, fishing, and construction industries.

- Nylon coated Stainless Steel Wire rope: This type of wire rope is coated with a layer of nylon material, which provides additional resistance to abrasion, chemicals, and UV rays. It is commonly used in indoor applications, such as gym equipment, garage doors, and industrial machinery.

- Coated stainless steel wire rope: This refers to any type of wire rope that has been coated with a layer of material (such as PVC, nylon, or polypropylene) to enhance its durability, flexibility, and appearance. Coated wire ropes are often used in applications that require high strength, low stretch, and resistance to wear and tear.

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