Founded as a wire EDM shop in 2005, Greatspring is no stranger to working within +/- 0.001mm tolerances. Compared to conventional CNC Machining, wire EDM is a much more accurate, but slower erosion process. That doesn’t mean that you should settle for long lead times or disappointing throughput.

What are the requirements for wire cutting during processing?

【1】Reasonable choice of workpiece material

In order to reduce the deformation of the workpiece caused by the wire cutting process, materials with good forging performance, good permeability, and small heat treatment deformation should be selected. The material of the work piece shall be subjected to standard heat treatment according to the technical requirements.

【2】Machining threaded holes

For the processing of closed holes and some punches, wire holes need to be processed before online cutting. The position of the threaded hole should be consistent with the starting point of processing during programming.

【3】Types of electrode wire

The wire cutting process in fast-moving wire generally uses molybdenum wire with a diameter of 0.18 mm as the electrode wire; the wire electrode wire for slow-moving wire cutting generally uses brass wire, in addition to galvanized wire, etc. The diameter of the electrode wire can be based on the machining accuracy. It is required to choose, try to choose electrode wire with a diameter not less than 0.2mm to obtain a higher cutting speed and reduce the risk of wire interruption during processing.

【4】Clamping and correction of workpiece

Wire cutting machine processing selects the appropriate clamping method according to the processing shape and size of the workpiece, and determines the position of the workpiece to be clamped. If the clamping methods of plate parts, rotating parts, and block parts are different, you can choose fixtures or design fixtures to clamp the workpiece. After the workpiece is clamped, it needs to be corrected. Generally, it is to check the perpendicularity and flatness of the workpiece clamping, and correct the axial parallelism of the reference plane of the workpiece and the machine tool.

【5】Threading and schooling

Wrap the wire electrode correctly on each part of the wire running mechanism to maintain a certain tension on the wire electrode. Use appropriate methods to correct the verticality of the electrode wire, such as wire alignment with a aligner, wire alignment with sparks, etc.

【6】Positioning of the wire electrode

Before wire cutting, the electrode wire should be accurately positioned to the starting coordinate position of the cutting. The adjustment methods include visual inspection, spark method, and automatic alignment. The current wire-cutting machine tools all have the function of contact sensing, and they all have the functions of automatic edge finding and automatic center finding. The alignment accuracy is high, and it is very convenient for electrode wire positioning. The operation method varies from machine tool to machine tool.

Two separate, redundant automation cells assure our wire EDM machines stay running while our competitors’ machines are in sleep mode. If you have high-volume needs, our productivity can’t be matched.

If you need high-precision and high-repeatability for a high-volume of parts, then contact us today.

http://www.cncprecisionparts.com/