Easy Four Steps to Quickly Master CNC Wire Cutting Processing

If the CNC wire cutting process is applicable, the choice between intermediate wire cutting and slow wire cutting should be made based on the part's processing requirements (such as surface quality, dimensional accuracy, etc.). For parts requiring high dimensional accuracy and good surface roughness, CNC wire cutting should be performed using a slow steel wire cutting machine. Preparations for CNC wire cutting:

1) Reasonable selection of workpiece material

To reduce deformation caused by wire cutting, materials with good forging performance, permeability, and minimal heat treatment deformation should be selected. The workpiece material should undergo standardized heat treatment according to technical requirements.

2) Wire hole processing

Closed holes and some stamped shapes require steel wire holes to be processed before online machining. The position of the wire hole must match the machining start point specified during programming.

3) Selection of electrode wire type

Intermediate wire cutting generally uses molybdenum wire with a diameter of 0.18 mm as the electrode wire. Electrode wires for slow wire cutting usually use brass wire, galvanized wire, etc. The diameter of the electrode wire can be selected according to machining accuracy requirements. Using electrode wires with a diameter less than or equal to 0.2 mm can achieve higher cutting speeds and reduce the risk of wire breakage during machining.

4) Workpiece clamping and correction

According to the form and size of the workpiece, select an appropriate clamping method and determine the position of the clamped workpiece. If the clamping methods differ for plate parts, rotary parts, and block parts, special fixtures can be chosen or custom fixtures designed to fix the workpiece. After clamping, it is common to check the normality and flatness of the workpiece fixture and adjust the parallelism of the workpiece reference plane relative to the machine tool axis.

5) Threading and correcting the wire

Correctly wind the electrode wire on various parts of the walking mechanism to maintain a certain tension on the electrode wire. Use appropriate methods to correct the verticality of the electrode wire (such as correctors, spark correctors, etc.).

6) Electrode wire position

Before CNC wire cutting, the electrode wire must be accurately placed at the starting coordinate position of the cut. Adjustment methods include visual measurement, spark methods, automatic amniotic fluid, etc. Currently, CNC wire cutting machines have contact sensing functions and features like automatic edge finding and automatic center finding, which provide high accuracy and make electrode wire positioning very convenient. The operation method depends on the machine tool.

CNC wire cutting programming is the key to the entire process. The machine tool processes according to the CNC program, and the accuracy of the program directly affects the processing form and precision. In actual production, most use automatic programming methods.

After completing CNC wire cutting programming, before formal cutting, the CNC program must be checked and verified to ensure accuracy. The CNC system of the wire cutting machine provides program verification methods. One common method is the picture check method, mainly used to check for syntax errors in the program and compliance with pattern processing configuration files. Another is the dry run check method, used to check the actual machining situation of the program, verify whether there are collisions or interferences during machining, and whether machine movements meet processing requirements. By simulating dynamic machining conditions, the program and machining trajectory path are comprehensively verified. For molds requiring high dimensional accuracy, punches, and mold fit clearances, trial cuts can be made using plate materials to check dimensional accuracy and fit clearances. If inconsistencies are found, the program should be promptly modified until verification passes before formal machining. During machining, electrical and non-electrical parameters can be adjusted according to the machining status to maintain optimal discharge conditions. After formal cutting ends, the workpiece should not be hastily removed; ensure the start and end coordinate points are consistent. If problems are found, corrective measures should be taken promptly.