Design and Implementation of a Versatile Flexible 3D Wire Bending Machine with Accuracy Algorithm

This paper presents the development of a flexible wire bending machine designed to overcome limitations associ - ated with traditional counterparts. Traditionally, wire bending machines are often designed for specific purposes, necessitate complex coding, are prohibitively expensive, or are constrained to producing two-dimensional shapes. To address these challenges, our study begins with an extensive review of existing research in the field, fol - lowed by the selection of a concept derived from this analysis. The methodology encompasses the entire design and manufacturing process. Initial research guides the concept selection, which is then translated into a practical design using SolidWorks simulations. The theoretical foundation involves mathematical formulations for each machine component, ranging from the wire feeding system to the bidirectional and 3D bending mechanisms. Main actuators are chosen based on calculated parameters, and the machine is assembled, incorporating a CNC system. The machine is tested first without wire and subsequently with the bending of an aluminum (1350-H26), 3.2 mm diameter wire, copper with 3.25 mm diameter and steel with 2.5 mm diameter. The results demonstrate high ac - curacy performance and underscore the significance of considering spring back and bend allowance for precision in both 2D and 3D wire configurations. This study not only contributes to the design and fabrication of a flexible wire bending machine but also addresses the shortcomings of traditional counterparts, making wire bending more accessible, versatile, and cost-effective.