Interpolation Algorithm for Taper Trajectory with Tool Compensation in WEDM Based on Unit Arc Length Incremental Interpolation Method

Wire Electrical Discharge Machining (WEDM) is extensively applied in the mold and die industry, as well as in aerospace sectors, for the processing of components with complex surface geometries. The unit arc length incremental interpolation method (UALI) is a suitable approach for achieving high-precision four-axis simultaneous direct interpolation of wire cutting trajectories. To address the shortcomings and deficiencies of current UALI when considering tool radius compensation or wire electrode wear compensation, particularly in the handling of interpolation points at corners where multiple trajectories intersect, this paper proposes a tool compensation trajectory generation algorithm based on UALI. Simultaneously, taking taper components as an example, a corner processing strategy that considers the intersection of straight lines and arcs is introduced. To evaluate the superiority and limitations of the proposed algorithm, this paper includes an analysis of interpolation results and machining experiments conducted on a taper component. The results demonstrate that the proposed algorithm exhibits better adaptability and, compared to conventional algorithms, significantly improves geometric accuracy.