Processing technology of the hottest wire cutting

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Wire cutting processing technology

www.mechnet com. cn "> WEDM machinist a has three simulation input channels: one load, one electronic extensometer, and one expanded channel technique:

under certain equipment conditions, reasonable formulation of processing route is an important link to ensure the processing quality of workpiece. The process of WEDM machining mold or parts can generally be divided into the following steps. Analyze and review the drawings, and the analysis of drawings is important to ensure the processing quality of workpiece and the integration of workpiece Technical indicators are the decisive first step

the investment scope can be large or small

1. Analyze and review the drawing

the analysis drawing is the first step of decisive significance to ensure the workpiece processing quality and the comprehensive technical indicators of the workpiece. Taking the blanking die as an example, when digesting the pattern, we should first pick out the workpiece pattern that cannot or is not easy to be processed by WEDM, which roughly includes the following:

⑴ the workpiece with high requirements for surface roughness and dimensional accuracy that cannot be manually ground after cutting

⑵ workpieces whose narrow gap is smaller than the diameter of electrode wire plus discharge gap, or workpieces with rounded corners formed by the discharge gap of rigid electrode derrick are not allowed at the inner corners of the figure

⑶ non conductive materials

⑷ parts with thickness exceeding the wire frame span

⑷ workpiece with machining length exceeding the effective stroke length of X, y carriage and high accuracy requirements. Under the condition of conforming to the wire cutting process, careful consideration should be given to the surface roughness, dimensional accuracy, workpiece thickness, workpiece material, size, fit clearance and punching thickness

2. Programming precautions:

(1) determination of die clearance and transition circle radius, and reasonable determination of die clearance. The reasonable selection of die clearance is one of the key factors related to the service life of the die and the burr size of the stamping part. The die clearance of different materials is generally selected in the following range: soft blanking materials, such as red copper, soft aluminum, semi hard aluminum, plywood, red paperboard, mica sheet, etc., and the punch die clearance can be selected as 10% - 15% of the thickness of the blanking material. For hard blanking materials, such as iron sheet, steel sheet, silicon steel sheet, etc., the clearance between punch and die can be 15% - 20% of the blanking thickness. This is the actual empirical data of some wire cutting blanking dies, which is smaller than the internationally popular large gap stamping dies. Because there is a brittle melting layer on the surface of the workpiece processed by wire cutting, the greater the processing electrical parameters, the worse the surface roughness of the workpiece and the thicker the melting layer. With the increase of die punching times, this brittle surface will gradually wear away, and the die gap will gradually increase. Reasonably determine the radius of transition circle. In order to improve the service life of general cold stamping dies, transition circles should be added at the intersection of lines, lines and circles, especially at the corners of small angles. The size of the transition circle can be considered according to the thickness of the blanking material, the shape and required service life of the die and the technical conditions of the stamping part. With the thickness of the stamping part, the transition circle can also be increased correspondingly. Generally, it can be selected in the range of 0.1-0.5 mm. For the transition circle with thin punching material, small die fit clearance and punching parts that are not allowed to increase, in order to obtain a good punch die fit clearance, a transition circle is generally added at the corner of the figure. Because the electrode wire processing track will naturally process a transition circle Custer with a radius equal to the electrode wire radius plus one-sided discharge gap at the inner corner

(2) when calculating and writing the processing program, it is necessary to select a reasonable clamping position according to the batching situation, and determine a reasonable starting point and cutting route at the same time. The starting point should be at the corner of the figure or at the part where the convex tip is easy to be repaired. The cutting route is mainly based on the principle of preventing customers from reducing the reprocessing of steel plates or reducing the deformation of molds. Generally, it should be considered to make the final cutting of graphics close to the clamping side easier

(3) for dies with high dimensional accuracy and small fitting clearance between male and female dies, thin materials must be used for trial cutting, and the fine sections and fitting clearance can be checked on the cutting parts. If it is found that it does not meet the requirements, it should be analyzed in time to find out the problems, and modify the program until it is qualified before the formal processing of the mold. This step is an important step to avoid workpiece scrapping

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