A system for converting a CNC milling machine to a CNC wire saw machine, the CNC milling machine comprising:
- a worktable configured to support a workpiece on a top surface of the worktable;
- a first gantry mounted over the worktable, the first gantry configured to be slidable along a first axis relative to the worktable;
- and
- a first carriage mounted on a transversely disposed section of the first gantry, the first carriage configured to be slidable on the transversely disposed section of the first gantry along a second axis relative to the worktable, the second axis perpendicular to the first axis;
- a spindle mounted on and moveable with the first carriage, and
- wherein the system comprises:
- a second gantry configured to be coupled and moveable with the first gantry along the first axis, the second gantry comprising;
- a pair of parallel elongated support legs, each elongated support leg of the pair of parallel elongated support legs positioned on a respective side of the worktable;
- and
- an upper transverse beam laid across upper ends of the pair of parallel elongated support legs along the second axis;
- a second carriage slidably mounted on the upper transverse beam, the second carriage configured to be coupled with the first carriage, the second carriage further configured to be moveable with the first carriage along the second axis;
- a gearbox disposed within and moveable with the second carriage, the gearbox configured to be coupled with the spindle;
- a drive pulley coupled with the spindle via the gearbox, the gear box further configured to transfer a rotational movement of the spindle to the drive pulley;
- a plurality of idler pulleys mounted on the second gantry, the plurality of idler pulleys rotatable on a plane of rotation perpendicular to a plane of rotation of the spindle;
- and
- a wire tension mechanism, comprising:
- an extension leg attached to or integrally formed with a first elongated support leg of the pair of parallel elongated support legs, the extension leg extended from the top end of the first elongated support leg along a longitudinal axis of the first elongated support leg;
- a curved guide rail, a first end of the curved guide rail attached to or integrally formed with a top end of the extension leg, a second opposing end of the curved guide rail attached to or integrally formed with the top end of a second elongated support leg of the two elongated support legs, the curved guide rail bent downward on a transverse plane, the transverse plane parallel with the pair of parallel elongated support legs and the upper transverse beam;
- a vertical guide rail extended upward along a third axis from a top end of the second carriage, the third axis perpendicular to the second axis;
- a first bearing block slidably coupled with the vertical guide rail, the first bearing block moveable along the third axis, the first bearing block further comprising a follower coupled with and moveable along the curved guide rail;
- and
- a top tension wheel mounted on the first bearing block, the top tension wheel rotatable about a rotational axis perpendicular to the upper transverse beam;
- and
- a wire attached to the drive pulley, the plurality of idler pulleys, and the top tension wheel, the drive pulley configured to drive the wire to travel through the drive pulley, the plurality of idler pulleys, and the top tension wheel, in an endless wire loop.