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How to ensure the quality of wire cutting

How to ensure the quality of wire cutting

How to ensure the quality of wire cutting

How to ensure the quality of wire cutting

How
Intheprocessofwirecutting,howtoensurethequalityofwirecuttingisaveryimportantissueinmoldprocessing.Ingeneral,payattentiontothefollowingaspectswhencuttingonline:(1)Selecttheappropriatemoldmaterial  Wirecuttingisgenerallyperformedaftertheblankishardened.IfcarbontoolsteelssuchasT8AandT10Aareused,itisdifficulttohardenandthehardenedlayerisshallow.Afteruse,thehardenedlayermaybewornawayandthehardnessDecreasedsignificantly.Inordertoimprovetheservicelifeandmachiningaccuracyofwirecuttingmolds,alloytoolsteelsorhardalloyswithgoodhardenabilityshouldbeused.Thehardnessofthesematerialsfromthesurfacelayertothecenterisnotsignificantlyreduced.(2)Improvetheaccuracyofmechanicaltransmission  Theaccuracyofmechanicaltransmissionhasagreatinfluenceonthemachiningaccuracy.Thedisplacementaccuracyofthetableandthemovementaccuracyoftheelectrodewiredirectlyaffectthemachiningaccuracy.Sincethemovementofthetableisdrivenbymultipletransmissionpairs,suchasgearpairs,screwnutpairs,etc.,theirtransmissionaccuracydirectlyaffectsthemachiningaccuracy.Themovementaccuracyoftheelectrodewireisalsogreatlyaffectedbytherotationaccuracyoftheguidewheel,unevenwearoftheguidewheel,andslackoftheelectrodewire.Itcanbeseenthatthelowprecisionofthemechanicaltransmissionhasagreatimpactontheprocessingquality.(3)Reductionofresidualstress  Whenwirecuttingisused,largepiecesofmetalwillbecutoff,therelativeequilibriumstateoftheinternalresidualstressofthematerialwillbedestroyed,andthestresswillberedistributed.Theresidualstressinthematerialissometimesmoreseriousthanthemachineprecisionandotherfactorsonthemachiningaccuracy,whichcanmakethedeformationvisibletothemacro,andeventhematerialwillbreakduringthecuttingprocess.Inordertoreducethedeformationcausedbyresidualstress,correspondingmeasuresshouldbetaken,suchascorrectselectionofheattreatmentspecifications;thecontouroftheworkpieceshouldbe8-100mmawayfromtheedgeoftheblank;agingtreatmentcanbeperformedbeforeonlinecutting;pre-processingbeforequenchingtoremovemostMargin;whenwirecutting,usethesecondarycuttingmethod,roughcuttheholeforthefirsttime,andfinecuttheholewhenthestressreachesanewbalance;choosethecorrectcuttingsequence,etc.Theabovemeasuresareofgreatbenefittoreducetheresidualstressinthematerial.(4)Reducesurfaceroughness  Thesurfaceroughnessofthemoldcavityhasagreatimpactonthequalityoftheplasticpart,andweshouldtrytoreducethesurfaceroughnesswhencutting.Tothisend,relevantmeasuresshouldbetaken.Iftheelectrodewireisnottightenough,itshouldbetightenedatanytime;thefeedspeedshouldbeadjustedappropriatelytoavoidspeedfluctuations;toolargeamechanicaltransmissiongapcaneasilycausetheelectrodewiretoshakeandincreasetheroughness.Forthisreason,itisnecessarytoadjustthetightnessofeachmechanicaltransmissionpartintime;correctlyselecttheelectricalparameterstoavoidthesinglepulsebeingtoolarge.Inaddition,thewirefeedspeedistoofastorjitteroccurs,whichwillalsoaffectthesurfaceroughnessofthepart.Theyarealldetrimentaltoqualityimprovement.
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