Processing of foamed polystyrene models using a hot wire tool

Abstract

To form three-dimensional foamed polystyrene models, cutting by milling has been used exclusively in engineering. With recent increases in the demands for processing in rapid prototyping, evaporative pattern casting, etc., improvements of the production speed are urgently required. In this study, we examined hot wire cutting, which has the advantage that it can not only cut the final shape to form in a single cutting pass, but it is also easy to collect and dispose of the chips. Therefore, we investigated a new processing method for the production of foamed polystyrene models using a hot wire tool. First, we obtained an approximation of the ruled surface, which was the aggregate of the straight line so that the wire tool can generate a curved surface. Next, software was developed to provide the NC data, which allowed the wire tool to be traced along these line elements through rotational transformation matrix theory. Then, we performed 3-dimensional processing tests to form foamed polystyrene models on a 5-axis controlling machine tool equipped with a Nichrome wire tool. Finally, we confirmed experimentally that it is possible to form warped surfaces of the required shape by hot-wire cutting.