What should I do if the wire cutting process is unstable?
First, let’s talk about how the wire cutting is processed under stable conditions – the molybdenum wire moves close to the workpiece until the gap is ionized and broken down, and the spark discharge will form corrosion under the action of extreme effects and thermal melting effects. The explosion and cleaning of the coolant makes the corrosion quickly drain out, and the new or high dielectric coefficient coolant ionizes the gap to restore the insulation, the gap expands, and the molybdenum wire is similar to the workpiece.
If any of the above-mentioned process factors, it will lead to unstable processing. After summarizing, the current problems and solutions are as follows:
1. The thickness of the workpiece to be cut is long, and the discharge distance is long, and it is difficult for water to enter. Cut high parts as far as possible with water-based cutting fluid. The water-based cutting fluid has significantly stronger chip removal ability than oil-based cutting fluid, and the flushing effect is better, and the cutting parts are much faster than oil-based fluids. Friends can try the effect of Suntory’s own Liangjie water baseline cutting fluid.
2. Material impurities, so that sampling and gap tracking are inaccurate. This situation is generally a common problem encountered in the shearing of iron castings.
3. The water explosion, cleaning, ionization elimination ability is poor, and the active ingredients are few. Mainly because the wire cutting working fluid is used for a long time and the working components are consumed too much, it is recommended to replenish or replace the new fluid in time.
4. The wire speed and trajectory are unstable, and the gap is chaotic. Check the line for vibration, check the bearings.
5. The material is deformed by stress, and the local elasticity is large, and the slight deformation of the cutting seam eats up the discharge gap. It is best to rest the workpiece material before cutting to relieve internal stress.
6. The frequency conversion tracking is tight and uncomfortable, and it is far away from the linear area of sampling voltage and frequency conversion speed. The frequency conversion must be adjusted.
7. The block of coordinate movement and the accumulation of thrust (crawling) make the discharge gap uncertain, and the tracking is inaccurate.
8. The inlet impedance is large or the contact is poor, and the sampling is unstable or far away from the discharge point. until the gap is identified incorrectly.