Views: 20 Author: Gree Daikin Mold Publish Time: 2024-07-19 Origin: Gree Daikin Mold
Wire-cut machining, also known as low-speed wire-cut machining, is a high-precision discharge machining technology that is often used to process small, complex-shaped and high-precision parts. The following is a detailed explanation of the principle of wire-cut machining and its processing technology:
Basic definition: Wire-cut machining is a CNC machining machine that uses a continuously moving thin metal wire (called an electrode wire, generally a copper wire) as an electrode to perform pulse spark discharge on the workpiece, generate a high temperature of more than 6000 degrees, erode the metal, and cut it into a workpiece.
Working principle: The principle of wire-cut machining is the phenomenon of continuous discharge to remove metal in the gap between the wire electrode and the workpiece. When the flexible electrode wire and the workpiece are close to the discharge gap commonly considered (for example, 8 to 10 μm), spark discharge does not occur immediately. Only when the workpiece bends the electrode wire and deflects it by a certain distance (several microns to tens of microns) does normal spark discharge occur. At this time, for every 1 μm of wire electrode feed, the discharge gap does not decrease by 1 μm, but the electrode wire increases a little wire tension, and the workpiece increases a little lateral pressure.
Processing characteristics: Since the slow-moving wire cutting machine adopts the method of continuous wire feeding, even if the wire electrode is worn out, it can be continuously replenished, so the processing accuracy of parts can be improved. The surface roughness of the workpiece processed by the slow-moving wire cutting machine can usually reach Ra=0.8μm and above, and its roundness error, linear error and dimensional error are much better than those of the fast-moving wire cutting machine.
Coreless cutting (chipless cutting): When processing very small shapes, the electrode wire follows a dense trajectory within the processing shape without generating any waste. It is mainly used for processing small holes and achieving the purpose of unattended machines.
Male and female molds are produced at the same time: For the wire cutting processing of punching dies and blanking dies, by designing a suitable angle and using wire cutting for taper processing, the punch and the die can be processed on a template at one time, which greatly improves production efficiency and reduces material costs.
Processing of mating parts: The key is to choose the correct electrode wire offset, the appropriate matching clearance and sharp corner clearance. The processing steps include processing the punch, adjusting the offset, calculating the offset and fit of the processing die.
Linear cutting: When a series of cylindrical punches need to be processed, these punch shapes can be designed on a template and kept connected to each other, and finally they can be linearly cut apart.
Material preparation:
Select materials without internal stress. In particular, the internal stress of quenched materials is large, and tempering or even ultra-deep cryogenic treatment is required to remove the internal stress. Rough processing and aging treatment before processing to release cutting stress can eliminate most of the material stress.
Process parameter optimization:
According to the workpiece material, shape and processing requirements, select appropriate process parameters such as current, pulse time, penetration speed and tension, water pressure, etc. to reduce thermal deformation and mechanical deformation during processing.
Electrode selection:
Selecting electrodes suitable for the shape of the workpiece can reduce the mechanical deformation of the workpiece. Thinner electrodes can reduce processing errors.
Temperature control:
During the processing, the processing temperature is controlled by processing fluid and cooling device, usually controlled at 23±2℃ to reduce the thermal deformation of the workpiece.
Selection of starting cutting position and support position:
Select the appropriate starting cutting position and support position. If it is selected in an inappropriate place, the support part of the material will become fragile after roughing, resulting in deformation. The starting cutting position and support position should be selected where the support part is relatively strong after roughing.
Increase support:
For large or long workpieces, multiple supports should be made instead of one, which can effectively prevent deformation. This is especially important when cutting the shape of punches, inserts, etc.
Wire cutting with wire holes:
When cutting the shape, if the wire feeding causes deformation, wire cutting with wire holes will greatly improve it.
Processing sequence and path planning:
Reasonably arrange the processing sequence and path to avoid excessive stress concentration during the processing process, thereby reducing deformation. Process the large hole first, then the small hole, to ensure that the time from the start of fine finishing to the completion of fine finishing is as short as possible.
Equipment maintenance and inspection:
Regularly maintain and inspect the wire-cutting processing equipment to ensure that the equipment is in good working condition.
The above is a detailed introduction to the principle of wire-cutting processing and its processing technology. Wire-cutting processing has been widely used in processing factories in aviation, automobile, medical and other industries with its high precision, high efficiency and high surface quality. We, Zhuhai Gree Daikin Precision Mould Co., Ltd., hope to become your most trusted mould partner with excellent craftsmanship, high-quality service and high professionalism. We look forward to establishing a long-term and stable mould cooperation relationship with you to help your products win more market share.
