WEDM processing steps and requirements
EDM wire cutting
is a technology to achieve the workpiece size processing. Under certain conditions of equipment, the rational development of processing technology is to ensure the quality of the workpiece processing an important part.
Analysis of the pattern to ensure the quality of workpiece processing and the overall technical indicators of the workpiece is a decisive first step. To punch die, for example, in the digestion of the first test to be difficult or difficult to use EDM wire cutting the workpiece pattern, generally have the following:
(1) the workpiece whose slit is smaller than the diameter of the electrode wire plus the discharge gap or the fillet formed by the corner of the figure with the discharge gap of the electrode derrick;
In line with the line cutting process conditions, should focus on the surface roughness, dimensional accuracy, the workpiece thickness, the workpiece material, size, with the gap and the thickness of the pieces and so carefully considered.
(2) reasonable to determine the die gap. The choice of die gap is one of the key factors related to the life of the mold and the size of the burrs. The dies of different materials are generally selected in the following ranges:
Soft punching materials, such as copper, soft aluminum, semi-hard aluminum, bakelite, red cardboard, mica, etc., convex and concave mold gap can be selected for the thickness of 10% -15%.
Hard punching materials, such as metal, steel, silicon steel, etc., convex and concave mold gap can be selected for the thickness of 15% -20%. This is some of the actual experience of wire cutting processing punching die data, than the international popular large gap die to be smaller. Because the surface of the workpiece is cut on the surface of the workpiece, the greater the processing parameters, the worse the surface roughness of the workpiece, the thicker the melting layer. With the increase in mold times, this layer of crisp loose surface will gradually wear away, is the mold gap gradually increased.
Reasonable determination of the radius of the transition circle. In order to improve the service life of the general cold die, in the line, line circle, far from the intersection, especially the small angle of the corner should be added rounded round. The size of the transition circle can be based on the thickness of the blanking material, the shape of the mold and the required life and the technical conditions of the pieces, with the red pieces of thick, the transition circle can also be a corresponding increase. Generally available in the range of 0.1-0.5 mm.
For the blank material is thin, the mold with the gap is small, the punch does not allow the increase of the transition circle, in order to get a good convex and concave mold with the gap, usually in the corner of the graphics should also add a transition circle. Because the electrode wire processing track will be processed at the corner of the natural radius of the electrode wire is equal to the radius of the single-sided discharge gap of the transition circle.
When programming, according to the situation of ingredients, select a reasonable clamping position, while determining a reasonable starting point and cutting routes. The starting point should be taken at the corner of the figure, or where the crown is easily removed. Cutting the main line to prevent or reduce the principle of deformation of the mold, the general should be considered close to the side of the graphics with the final cut for easy.
According to the procedures after the production of a single tape, we must put the program and the production of a good tape one by one proofreading, with a good proof of the tape to the program after the controller can try to try the model, the simple grasp of the workpiece can be processed directly The On the size of the high precision, convex and concave mold with a small gap between the mold, we must use thin material test cut, engaged in cutting pieces can check its accuracy and with the gap. If you find that does not meet the requirements, should be timely analysis, identify the problem, modify the program until qualified before the formal processing of mold. This step is to avoid an important part of the workpiece scrap.
According to the actual situation, can also be directly from the keyboard input, or from the programming machine directly to the program transfer to the controller.