Slow walking wire processing old broken wire machining plant needs to be how to deal with?

01What Should I Do If The Wire Keeps Breaking During Wire Cutting?

Wire Breakage Is One Of The Most Common Problems In Wire-Cut Machining. After Wire Breakage Occurs, Do Modify Parameters Randomly. Determine The Possible Cause Of Wire Breakage Based On The Machining Situation At The Time Then Take Corresponding Measures.

1) The Upper Surface Of The Cut Parts Has Large Ups Downs

Countermeasures: The Upper Surface Of The Cut Parts Has Large Ups Downs, The Upper Lower Water Nozzles Cannot Be Processed Face To Face, High-Pressure Water Flushing Cannot Be Effectively Performed, Resulting In Wire Breakage. This Situation Occurs In The Rough Processing Of The Machining Plant . Wire Breakage Can Be Avoided By Reducing The Discharge Energy. It Is Preferred To Reduce The Discharge Power P Value. When The Wire Is Still Broken After A Significant Reduction, Consider Reducing The Discharge Current I. Reducing P Will Reduce Some Processing Efficiency, But Reducing The Discharge Current Will Greatly Reduce The Processing Efficiency. Huiwen Zhizao Is A Machining Plant With More Than Ten Years Of CNC Processing Experience . It Has A Full Range Of Equipment, CNC Turning/Milling/Grinding/Drilling/Processing. Partners With Parts Processing Needs Are Welcome To Call Us For Quotes.

2) Inability To Effectively Flush With High Pressure Water

In 1), It Is Also Impossible To Achieve Effective High-Pressure Water Flushing, But That Is Determined By The Workpiece, We Cannot Change The Workpiece. In Actual Processing, There Are Many Reasons That Cannot Be Effectively High-Pressure Water Flushing, Which Can Be Improved Artificially. For Example, The Distance Between The Upper Nozzle The Upper Surface Of The Workpiece Is Too Large. This Situation Is Wrong. The Distance Between The Upper Nozzle The Upper Surface Of The Workpiece Should Be Reduced As Much As Possible. For Example, When Machining A Flat Plate, The Distance Should Be Controlled At About 0.1mm; In Addition, Check Whether The Upper Lower Water Nozzles Are Damaged. If Damaged, Please Replace Them In Time.

3) Improper Electrical Parameters

Countermeasures: Please Carefully Check Whether The Selected Discharge Parameters Are Correct, Whether The Wrong Workpiece Height Electrode Wire Type Is Selected, Etc.; If The Discharge Parameters Of The Machining Plant Are Stable Enough, You Can Improve It By Reducing The P Value Reducing The Pulse Discharge Energy; If The Tension Value In The Parameter Is Too Large, The Electrode Wire Will Be Broken, The Wire Tension Should Be Reduced, Especially In Taper Processing; The Wire Speed In Rough Processing Is Too Low, Which Will Cause Wire Breakage, So Adjust It If Necessary.

4) Quality Issues Of Electrode Wire Workpiece Materials

Countermeasures: The Electrode Wire Used Is Of Poor Quality, The Coil Is Overlapped, Oxidized, Etc., High-Quality Electrode Wire Should Be Used; Reduce The P I Values Until The Wire Is Broken.

5) The Conductive Block Is Severely Worn Too Dirty; The Wire Guide Is Too Dirty, Causing Wire Scraping

Countermeasures: Check The Wear, Surface Roughness (Oxidation), Connection Of The Conductive Block Brush; Clean, Rotate Replace The Conductive Block; Clean The Guide Wire Parts.

6) The Wire Feeding Is Stable The Balance Wheel Vibrates Greatly

Countermeasure: Wire Feeding Fluctuation. Use A Tension Meter To Check The Tension Of The Electrode Wire Adjust It.

7) The Waste Wire In The Waste Wire Bucket Overflows Contacts The Machine Tool The Ground, Causing A Short Circuit.

Countermeasure: Put The Overflowed Waste Silk Back Into The Waste Silk Bucket Clean The Waste Silk Bucket In Time.

02 What Should I Do If The Wire Cutting Processing Is Inefficient?

1) No Veneer Processing, Which Reduces The P I Values

Countermeasures: Adjust The Z Axis, Try To Process The Surface As Much As Possible. If The P Value I Value Must Be Reduced, It Should Be Moderate Too Much. Huiwen Intelligent Manufacturing Has Long Been Committed To The Processing Of High-Precision, High-Difficulty, Easy-To-Deform Metal Plastic Parts , The Small Medium-Volume Production Manufacturing Of Light Alloy Composite Material Parts (Such As Aluminum Alloy, Carbon Fiber, Etc.),  The Procurement Customization Of Robot Parts .

2) Improper Electrical Parameters

Countermeasures: A Reasonable Process Sequence File According To The Processing Requirements; Check Whether The ACO Adaptive Function Is Selected. When The Cutting State Is Stable, ACO Can Be Canceled; If There Are Many Corners In The Machining Plant, The Machine Tool Will Use The Corner Strategy. The Corner Strategy Can Be Appropriately Reduced According To The Processing Accuracy Requirements.

3) The Workpiece Is Deformed Cannot Be Trimmed; When Trimming The Die, The Main Cutting Speed Is Limited The Trimming Speed Is Slow

Countermeasures: Arrange The Process Reasonably To Reduce Material Deformation; When Repairing The Mold, Set A Reasonable Speed Limit For The Main Cutting To Avoid Too Fast Speed Failure To Cut The Excess.

4) The Main Cutting Efficiency Is Lower Than Before

Countermeasures: Perform Maintenance On The Machine Tool In A Timely Manner. Check Whether The Cooling Water Of The Conductive Block Is Normal; Check Whether The Lower Guide Wheel Rotates Flexibly; Check Whether The Wire Collection Wheel Is Normal; Check The Wire Tension Wire Speed, Readjust Them If Necessary; Check Clean The Wire Guide Nozzle Conductive Block During Machining.

03How To Prevent Temperature Difference Causing Errors In Wire-Cut Processing?

1) The Temperature Range For High-Precision Wire-Cut Machining To Ensure Working Accuracy Is 20±1º. If This Condition Cannot Be Achieved, The Most Important Condition Is To Control The Temperature Fluctuation Range, Which Should Preferably Exceed ±3º.

2) Before Working On The Parts, Soak Rinse Them In The Working Fluid For A Period Of Time, Then Align Process Them, Which Will Help Ensure Accuracy.

3) Larger Parts Are Best Completed In One Start-Up. If The Processing Is Stopped For A Long Time (Such As One Night), It Is Difficult To Ensure The Processing Accuracy. If The Downtime During One Processing Exceeds Two Hours, It Should Be Flushed For More Than Half An Hour Before Continuing Processing To Reduce The Error Caused By Temperature Difference. We Have The Ability To Participate With Customers The Engineering Development Of New Products Until The New Products Enter Formal Mass Production. We Can Improve The Processing Process For Customers To Reduce Costs While Controlling Product Quality. We Have Our Own Factory With Many Advanced CNC Precision Processing Equipment. We Have An Engineering Quality Team With Rich Technical Management Experience To Guarantee Our Services Provide Customers With Refined First-Class Precision Parts Processing Products.

04How To Prevent Cutting Deformation When Processing Punches?

In Actual Production Processing, Due To The Residual Stress Deformation Inside The Workpiece Blank The Thermal Stress Deformation Caused By Discharge, The Threading Hole Should Be Processed First For Closed Cutting To Avoid Deformation Caused By Open Cutting As Much As Possible.

If Closed-Form Cutting Cannot Be Performed Due To The Size Of The Workpiece Blank, For Square Blanks, Attention Should Be Paid To Selecting A Good Cutting Route ( Cutting Direction) When Programming. The Cutting Route Should Be Conducive To Ensuring That The Workpiece Is Always Kept In The Same Coordinate System With The Fixture (Clamping Support Frame) During The Processing Process To Avoid The Influence Of Stress Deformation. The Fixture Is Fixed At The Left End, The Cutting Is Carried Out In A Counterclockwise Direction The Left Side Of The Gourd-Shaped Punch. The Entire Blank Is Divided Into Left Right Parts According To The Cutting Route. As The Material Connecting The Left Right Sides Of The Blank Is Cut Smaller Smaller, The Right Side Of The Blank Gradually Separates The Fixture, Cannot Resist The Internal Residual Stress Deforms, The Workpiece Also Deforms Accordingly. If Cutting Is Carried Out In A Clockwise Direction, The Workpiece Remains On The Left Side Of The Blank, Close To The Clamping Part. Most Of The Cutting Process Keeps The Workpiece The Fixture In The Same Coordinate System, With Good Rigidity, Avoiding Stress Deformation. In General, A Reasonable Cutting Route Should Arrange The Cutting Section The Workpiece Is Separated The Clamping Part At The End Of The Total Cutting Program, That Is, The Pause Point (Support Part) Is Left Near The Clamping End Of The Blank.

05What Is The Cutting Process Of High-Precision Multi-Hole Concave Template?

Before The Slow Wire Cutting Process Of High-Precision Multi-Shaped Hole Recessed Template, The Template Has Been Cold-Processed Hot-Processed, A Large Residual Stress Has Been Generated Inside. The Residual Stress Is A Relatively Balanced Stress System. When A Large Amount Of Waste Is Removed By Online Cutting, The Stress Is Released As The Balance Is Destroyed. Therefore, When The Template Is Cut Online , With The Effect Of The Original Internal Stress The Influence Of The Processing Thermal Stress Generated By Spark Discharge, Non-Directional Irregular Deformation Will Occur, Making The Subsequent Cutting Thickness Uneven, Affecting The Processing Quality Processing Accuracy.

In View Of This Situation, For Templates With Relatively High Precision Requirements, Four Cutting Processes Are Usually Adopted. The First Cutting Will Cut Off All The Waste Materials Of The Mold Holes. After The Waste Materials Are Taken Out, The Automatic Shifting Function Of The Machine Tool Will Complete The Second, Third Fourth Cutting. A Cutting The First Time, Take The Waste Materials → B Cutting The First Time, Take The Waste Materials → C Cutting The First Time, Take The Waste Materials → … → N Cutting The First Time, Take The Waste Materials → A Cutting The Second Time → B Cutting The Second Time → … → N Cutting The Second Time → A Cutting The Third Time → … → N Cutting The Third Time → A Cutting The Fourth Time → … → N Cutting The Fourth Time, The Processing Is Completed. This Cutting Method Can Make Each Mold Hole Have Enough Time To Release The Internal Stress After Processing, Can Reduce The Mutual Influence Micro Deformation Of Each Mold Hole Caused By Different Processing Sequences To A Minimum, So As To Better Ensure The Processing Size Accuracy Of The Template. However, This Processing Time Is Too Long, The Number Of Wire Threading Is Large, The Workload Is Large, The Manufacturing Cost Of The Template Is Increased. In Addition, The Machine Tool Itself Will Also Produce Creep With The Extension Of Processing Time Temperature Fluctuations. Therefore, According To Actual Measurement Comparison, If The Processing Accuracy Allows, The Template Can Adopt The First Unified Processing To Take The Waste Unchanged, Cut The Following 2, 3, 4 Times Together (I.E. A Cuts The Second Time, Without Shifting Removing The Wire, Then Cuts The 3rd 4th Times → B → C... → N), Omit The 4th Cutting Do 3 Cuttings. In This Way, After Cutting, The Shape Position Dimensions Basically Meet The Requirements After Measurement. This Only Improves Production Efficiency, But Also Reduces Labor, Thus Reduces The Manufacturing Cost Of The Template.

06How To Arrange Long-Term Unmanned Operation Of Multi-Cavity Parts?

(1) For Some Multi-Cavity Parts With A Large Cutting Workload, They Can Be Arranged At Night Processed By Unmanned Operation, Which Can Save Costs Improve The Utilization Rate Of Machine Tools. Each Of The Multiple Cavities Must Set A Pause Reserve, Leaving A Section Uncut To Ensure That The Parts Do Fall Off, The Remaining Contours Are Cut Multiple Times To Meet The Processing Requirements. When In The Pause Reserve Position, The Machine Tool Automatically Cuts The Wire Moves To The Wire Threading Hole Position Of The Next Cavity. The Machine Tool Automatically Threads The Wire Then Continues Processing. The Process Of Cutting, Shifting, Threading, Processing Is Performed Multiple Times Until All Cavities Are Processed. In This Way, No Core Material Falls During The Cutting Process, No Human Intervention Is Required. When Human Intervention Is Required, The Material Is Cut Picked Up To Complete The Processing Of The Pause Reserve Section. In Order To Ensure The Smooth Automatic Threading During The Processing, The Diameter Of The Threading Hole Should Be As Large As Possible. Huiwen Zhizao Supports The Processing Of Metals (Such As Aluminum Alloys, Stainless Steel, Carbon Steel, Titanium Alloys, Magnesium Alloys , Copper, Etc.) Non-Metals (ABS, Plexiglass, Teflon PTFE, PEEK, PC, Saigang POM, Etc.). We Also Provide One-Stop Services For Various Post-Processing Such As Sandblasting Oxidation, Electroplating, Silk Screen Printing, Laser, Etc.

(2) For The Processing Of Multiple Small Cavities, It Is Convenient To Set A Pause Reserve Due To The Small Core Of The Material, Short Circuit Is Prone To Occur. The Coreless Cutting Method Can Achieve The Purpose Of Unattended Machine.