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How to Select the Configuration for a Wire-Cut EDM Machine Since the year 2000, manufacturers have invested significant resources in enhancing the processing speed and precision of medium-speed wire-cutting EDM machines. Despite considerable effort devoted to meticulously developing these machines, the results have consistently fallen short of expectations. In recent years, medium-speed wire-cutting EDM machines have entered a mature phase, achieving new heights in machining precision, speed, and surface finish. Gradually gaining market recognition, their demand has risen year after year. Yet, for general users, selecting and configuring these machines to achieve optimal results remains a challenge, as the selection process is highly nuanced. Previously, standard high-speed wire-cutting machines equipped with medium-speed control cabinets could achieve repeatable machining and tool repair functions, effectively functioning as medium-speed machines. However, modern genuine medium-speed wire-cutting machines offer far more capabilities. Visually, medium-speed machines differ significantly from high-speed ones. Modern medium-speed machines feature an aesthetically pleasing, streamlined design with automatic wire tensioning. Their sealed construction prevents emulsion oil leakage. Optional configurations include linear guides, servo motors for drive systems, computer control cabinets with automatic programming capabilities, and data storage functionality.View Details
2025-03-03
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Wire-Cut EDM Machine Operation Process and Fundamental Knowledge Wire-Cut EDM Machine Operation Process and Fundamental Knowledge When selecting a wire cutting machine, customers should prioritize practicality. First, determine the required processing dimensions (length, width, height) for the workpiece. Based on these specific measurements, choose the appropriate wire cutting machine model. Operational issues are inevitable with wire cutting machines. Only by correctly identifying these problems and having them repaired by professional technicians can the machine maintain consistent performance. If customers encounter unfamiliar issues, they should contact the manufacturer for solutions. For non-professional high-speed wire cutting operators who are fascinated by the process, high-speed wire cutting holds an air of mystery. Understanding how to perform high-speed wire cutting has become knowledge many aspire to acquire. After reading this article, many readers will gain insight into these procedures. Step 1: Identify the Cutting Object When receiving a workpiece for processing, the operator must clearly identify the areas requiring wire cutting, along with the required dimensions and surface finish specifications. After clarifying these details, consider the cutting approach, how to position the workpiece on the machine, and how to determine the machining process. Although this first step seems complex, it can be broken down into several sub-steps. In practice, however, these are relatively straightforward. Once the primary point is established, the subsequent steps can be completed efficiently. Step 2: Drawing and Programming This step demands the highest technical skill and knowledge. First, open the control panel of the high-speed wire-cutting EDM machine. Click “Return” with the mouse to enter drawing mode and proceed according to the shape determined in the previous step. Drawing requires programming. After programming, follow this sequence: Press “Execute 1” → Enter compensation gap value of 0.1mm → Post-process → Save G-code machining file → Save file name: 81 → Save to HF directory → Return to control panel → Read disk → 81 → Confirm. Step 3: Install the Electrode Wire First load the electrode wire, then thread it. Rotate the wire reel to its rightmost travel limit, tighten the limit switch, and secure one end of the electrode wire to the reel with a screw. Place the wire spool over the threading rod, tighten the nut, and ensure the wire won't fall off the spool. Use the crank handle to rotate the reel. When the reel approaches its opposite travel limit, cut the electrode wire. After threading the electrode wire, crank the spool clockwise over ten turns, then tighten the left-end limit switch. Step 4: Mounting the Workpiece Ensure the workpiece fits within the machine's working envelope. Numerous mounting details require attention, which I won't elaborate on here. Step 5: Process the Workpiece Operate the control system to initiate machining, as modern wire-cutting machines are now automated. Step 6: Inspect Finished Product Quality Measure dimensions with a gauge and verify surface smoothness meets specifications. The above outlines the wire-cutting process for high-speed wire-cutting machines. In practice, the programming for these machines is quite complex and requires individuals with a solid knowledge background to fully master.View Details
2025-03-03
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How to Resolve Vibration Issues in the Wire Spool of a Wire-Cut EDM Machine The bearings, shafts, and other components inside the wire spool of a medium-speed wire-cutting machine often develop gaps due to wear. This can easily cause the machine to vibrate, leading to wire breakage. Therefore, it is essential to promptly replace worn bearings, shafts, and other components within the machine. When the wire-reel of a medium-speed wire-cutting machine changes direction, failure to disconnect the high-frequency power supply can cause the molybdenum wire to burn out rapidly due to excessive heat. Therefore, it is crucial to verify that the limit switch at the rear of the wire-reel is functioning properly and has not malfunctioned. The wire-feeding mechanism of the medium-speed wire-cutting machine comprises guide wheels, the wire-reel, and the wire-frame. As the internal precision of this mechanism degrades, axial play and radial runout within the wire-reel shaft may occur. Here, “precision” primarily refers to the accuracy of the drive bearings. If radial runout occurs between the wire spools, the tension on the electrode wire gradually decreases, causing slack. In severe cases, the molybdenum wire may disengage from the guide wheel groove or even break. Additionally, axial play between spools disrupts uniform wire feeding, sometimes leading to wire stacking. To maintain smooth rotation between the guide wheels and the wire-cutting machine's wire-holding spools, carefully monitor for any vibration in the molybdenum wire during reciprocating motion. If vibration occurs, thoroughly analyze the root cause. Additionally, the limit stop block at the rear end of the wire-cutting machine's wire spool must be properly adjusted. This prevents the spool from exceeding the machine's limit travel and causing wire breakage. If the rapidly moving molybdenum wire comes into contact with the stop block within the wire-guiding device of the medium-speed wire-cutting machine, grooves can easily form, leading to wire jamming and breakage. Therefore, timely replacement is essential. When operating the medium-speed wire-cutting machine, it is crucial to thoroughly inspect the precision of the wire-feeding mechanism.View Details
2025-03-03
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