In addition to wire breaks and working fluids, there are some relationships with other factors, such as wire speed, accuracy, feed rate, workpiece material, and so on. Therefore, in order to reduce broken wires during wire cutting, different materials should use the corresponding processing parameters.
1, take wire speed
The speed of the wire moving speed directly affects the residence time and the number of discharges of the electrode wire in the processing zone, thereby affecting the loss of the wire electrode. Since the diameter of the electrode wire in the wire cutting process is small, if the electrode wire moves too slowly, multiple discharges may occur at a certain point on the wire electrode, so that the amount of erosion at this point is too large, and the wire tension and the spark discharge play a role in the explosion force. Very easy to break under the wire.
In addition, by increasing the threading speed of the heating wire, the working fluid can be easily brought into a narrow processing gap, the cooling of the electrode wire can be strengthened, and the electrocorrosion products can be brought out of the gap. However, high threading speed will increase the vibration of the electrode wire, and it is also easy to break the wire, and the accuracy of the machined surface is reduced, and the surface roughness value is increased. Therefore, under the condition that the electrode wire allows one point of continuous discharge, it is necessary to adjust the wire feed speed according to the discharge frequency in conjunction with the thickness of the workpiece.
2, feed speed
The ideal line cutting should be the feed speed to track its line processing speed, feed too fast, exceeding the possible removal rate of the workpiece, easily lead to frequent short circuit, the cutting speed is slow, the workpiece surface roughness is also poor, the upper and lower end surface The cut seam is yellow and may even break. If the feed rate is too slow and lags behind the possible removal rate of the workpiece, it will easily cause frequent open circuit. Over-tracking and under-tracking are all direct factors that cause processing instability, which can easily cause broken wires and affect the surface processing quality.
3, feeding accuracy
To achieve an ideal tracking feed, the performance of the feed control system must be improved and the optimal feed rate must be adjusted manually. The precision of the guide wire mechanism will directly affect the quality of the electrode wire, and the low accuracy will cause deviation and vibration, which in turn will cause wire breakage.
The guide wire mechanism of the wire cutting machine is mainly composed of a wire storage tube, a wire holder and a guide wheel. When the precision of the guide wire mechanism is reduced, radial runout and axial turbulence of the wire storage drum may be caused. The radial run-out will reduce the tension of the wire, causing the wire to loosen, which will severely pull the wire out of the guide pulley groove. Axial turbulence will cause uneven distribution of the wire, resulting in overlapping phenomenon. If the wire rack is poor in rigidity, vibration and vibration will occur during movement, which will not only affect the accuracy but also cause wire breakage.
4, the electrode wire material and diameter
Electrode wire materials are copper, tungsten, molybdenum, tungsten molybdenum alloy, etc., its life is about 20% to 30% higher than that of molybdenum wire, and the broken wire phenomenon is significantly reduced. The tungsten-molybdenum alloy wire may be preferred for reducing broken wires because the elongation, tensile strength, and melting point of tungsten are more suitable than molybdenum for wire cutting. For low wire speed, 0.12-0.30mm galvanized brass wire can be used for high productivity, allowing larger peak current. If the tension of the electrode wire is kept uniform, the vibration is small, the processing is stable, the workpiece accuracy and surface roughness are correspondingly better, and the electrode wire has a longer life.
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