Computer integrated manufacture of complex dies for drawing n-circular wires.

This research is based on the idea of machining complex wire drawing die configurations that require drastically different shapes on the top and bottom die faces, by manipulating the workpiece at a minimum of four axes. A prototype rig motivated by four stepper motors and controlled by a micro-computer has been designed and manufactured for the fulfilment of this idea. On the basis of experimental evidence, it is apparent that the idea is applicable in the VEDM process. Several die shapes were successfully produced. Distortion occurred at the top surface of some of the dies produced. Experimental investigations showed that the main cause of that distortion was the backlash in the geared stepper motors. The software, which was one of the essential factors for this work, presented, in an informative way, the required results in a tabular and graphical form on a visual display unit. A "hard-copy" of the results was easily obtained if required.