In the process of processing light engraving and milling machines, there are often problems such as rough surface, grooves and reduced accuracy.

The reasons for this situation are usually as follows:

(1) The wire is too loose and shaken.

(2) The working fluid is too dirty.

(3) Improper selection of pulse parameters.

(4) Molybdenum wire groove of the guide wheel is too large.

(5) Coil cylinder different heart, etc.

Second, the solution: nothing more than tight wire, replace the working fluid to select the pulse parameter, replace the guide wheel or bearing. In addition to the above reasons, in the repair process, we also found that the keyway between the spindle of the winding simple flow motor and the friction coupling due to long-term repeated operation, resulting in the deformation of the keyway, and the machining surface groove caused by the increase of vibration of the large gap wire cylinder during the reversal.

How to get a good finish

Wire-cut finish is composed of two elements, one is the size of a single discharge etching pit, its RZ is usually 0.05 μ-1. Between 5 μs, which is secondary to the cut finish. The second is the convex and concave fringes caused by commutation, and its RZ is usually between 1 μ-50 μ, as large as 0. More than 1MM is also possible, which is the most important factor in the composition of wire cutting finish. At the same time, it is accompanied by black and white stripes, giving people a strong visual impact. It is easier to control the pit size caused by a single discharge by reducing the energy of a single pulse. Only the single pulse energy is small to a certain extent, resulting in a thicker workpiece cutting, or even a non-spark state of only short circuit and no discharge, which is similar to the fine specification in EDM, resulting in extremely low efficiency and unstable processing with poor chip removal ability. Moreover, the RZ caused by the discharge pitting is not in the same order of magnitude as the RZ caused by the commutating fringe, so it is most important to control the RZ accompanying the commutating fringe. The accuracy of the guide wheel and bearing, and the constancy of the tension in the up and down running cause the inconsistent motion track of the silk up and down. This mechanical factor is the main reason for the commutation.

Take the following measures to improve the finish to some extent:

1. Properly reduce the pulse width and peak current, that is, reduce the size of the pit.

2, the guide wheel and bearing to maintain good accuracy and smooth operation, reduce the silk shake, silk jump, so that the silk trajectory to maintain a line of displacement to minimize.

3, the wire to maintain the appropriate tension, and adjust the guide wheel and feed block, so that when the wire up and down, the tension in the working area remains unchanged.

4, the silk should not be too tight, the water should not be too new, the new water is certainly beneficial to the cutting efficiency, but the cutting finish is not new water.

5. Add a splint on each side of the thin workpiece so that the commutation stripes are buffered within the range of the splint.

1. XY movement is stable, accurate, good fidelity with follow-up, and non-blocked crawling is also extremely important.

2, maintain a stable loose frequency tracking.

3, the appropriate amount of cutting again or multiple cutting, in the case of a small amount of cutting the cutting surface sweep, dimensional accuracy and finish will have a beneficial effect, even sweep three times, will basically remove the commutation fringe, as long as the machine repeatedly positioning accuracy is high, the appropriate amount of progressive processing, will make the cutting surface finish increased by one to two orders of magnitude, The effect is similar to slow walking wire, and the time is not too much, which is one of the strengths of fast walking wire cutting machine.

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