How To Improve the Wire-Cutting Machining Process
The slow wire-cutting machining is one of the wire cutting, which is to utilize continuous moving fine wire as electrodes to remove the metal by the pulse spark erosion of the workpiece. And it’s mainly used for machining some complex shapes and small precision of workpieces, and depending on the speed different of wire electrode, the EDM machine is usually divided into two kinds: Low wire-cutting machining and thread-wire cutting machining.
In general, Low-wire cutting speed is low than 0.2m/s and the precision reaches 0.001mm, and the surface quality is also close to the grinding level, so the finished surface is very smoothly.
Below are methods to improve the Wire-Cutting Machining Process
Ensure high pressure water work well
Firstly, we need to check the high pressure pump in the loop, water valve, bypass water value, upper and lower nozzle holder, upper and lower nozzle and water pipe to ensure there is no any blockage and leakage.
When working, let the upper and lower nozzle close to the upper and lower surface of the workpiece as far as possible and noted that prevent the nozzle from being hit by the clamp and the crossbeam), so high pressure water spraying can work best. In the rough machining process, high pressure water in good condition, and which can keep insulation between the wire electrode and workpiece, and fast clean out the electric erosion and reduce the secondary discharge and short circuit phenomenon, thus to improve the cutting speed.
Ensure the lubrication water works well
Checking circulating pump in the loop, lubrication water valve, up and down nozzle holder and water pipe to be unobstructed, and the lubrication water must be fully to avoid the wire electrode cutting to the upper head of conducting lump and the lower head conducting wheel to reduce the cutting efficiency.
Ensure the ion degree of electrolyte
Generally, we say the electrolyte is deionized water which is good insulation and is good for discharging machining, so the concentration of ions is usually measured by ion. In general, we set ionic degree is 15s/cm in the user preferences menu. When machining one part, if the sensor in the clean water tank actually measured the ions over 15s/cm, this ion resin in the ion bottle should be replaced, if it’s still not possible to reduce the ionic degree, we need to check the ionic circuit right now.
Ensure the quality of the electrode wire
The machining speed is depend on the final machining materials of the electrode wire parts. Such as: when working the same part, the zinc wire XS25 is faster than the brass wire LS25.
Ensure the discharge circuit is connected well.
- Ensure the cable is connected well, includes in: the upper and lower head cable connection and the workbench cable connection. When the connection cable is found to be loose, we need to tighten it; when it has been oxidized, we need to remove the oxidized layer with brush in time.
- Check that the input and output point of the cable is correct
- Check the wire condition of the upper conductive block and the lower conducting wheel, whether it need to be adjusted or replaced.
- Check the lower machine head carbon brush wear condition, whether it should be replaced.
Adjust the discharge parameters properly
In general, it can be given automatically discharge parameter when EDM machining. For improve the speed of rough machining, we can appropriately adjust the below discharge parameters. Such as: reduce the servo benchmark average voltage, increase the pulse width and the short pulse time. (when this short pulse time is smaller than the pulse width, we need to increase the frequency of discharge in time)
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