Method for machining multiple cuts in a workpiece to a uniform depth

A method for maching a surface of an electrode of an electric discharge machine with a tool to provide multiple cuts having uniform depths comprising the steps of:

• a. orienting the electrode with respect to a reference coordinate;
• b. recording an expected position of the surface of the electrode with respect to the reference coordinate;
• c. advancing the tool toward the surface;
• d. sensing contact of the tool with the surface;
• e. advancing the tool a predetermined distance to thereby machine the electrode to a predetermined depth;
• f. recording a sensed position of the electrode with respect to the reference coordinate as a result of the contact of the tool with the surface;
• g. comparing the sensed position to the expected position and calculating a deviation of the surface from the reference coordinate;
• and
• h. using the deviation to monitor the position of the electrode to assure that the position of the surface of the electrode is accurately sensed during subsequent machining steps.

A method for machining a curved surface of a workpiece with a tool having an axis to provide multiple cuts normal to the surface and having uniform depths comprising the steps of:

• a. orienting the workpiece with respect to a reference coordinate;
• b. recording an expected position of the surface of the workpiece with respect to the reference coordinate;
• c. advancing the tool toward the surface;
• d. sensing contact of the tool with the surface;
• e. advancing the tool a predetermined distance to thereby machine the workpiece to a predetermined depth;
• f. recording a sensed position of the workpiece with respect to the reference point as a result of the contact of the tool with the surface;
• g. comparing the sensed position to the expected position and calculating a deviation of the surface from the reference coordinate;
• and
• h. using the deviation to monitor the position of the workpiece to assure that the position of the surface of the workpiece is accurately sensed during subsequent machining steps and to calculate an angle between the surface and the axis of the tool to assure that the axis of the tool is normal to the surface.