Summary:

How to solve the problem of interrupted wire in mid wire processing? The problem of wire breakage in intermediate wire processing has been studied both domestically and internationally for a long time. Below, we will take a look at how to solve the problem from various aspects such as expert research on intermediate wire processing.

Since the late 1980s, experts in the field of wire cutting have noticed that wire breakage in wire cutting is usually related to an increase in short circuits. They believe that both wire vibration and short circuits can cause a decrease in processing speed and increase the probability of wire breakage Subsequently, it was found that before the wire was broken, the discharge frequency would suddenly increase and concentrate on one point, causing local high temperature and resulting in the electrode wire being burned off This is the entire process of a broken wire in the middle of the journey The direct cause of wire breakage is the increase and concentration of thermal load in the input gap, which is caused by the instability of the machining process. Since the cause of wire breakage is the instability of the machining process, taking effective measures to quickly enter a stable state based on the unstable signal of the machining process is the fundamental way to overcome the problem of wire breakage.

1. Pulse power supply should have low loss performance of electrode wires. Pulse power supply is an important component of medium wire cutting machine tools and is the most critical device affecting the processing of medium wire cutting In the high-speed wire cutting process, the electrode wire is used back and forth. If there is any loss, it will directly affect the machining accuracy. When the loss is large, it will also increase the probability of wire breakage. Therefore, the pulse power supply of the medium wire cutting machine should have low loss performance for the electrode wire

2. Is the intermediate wire cooling system complete. When the cooling system on the intermediate wire cutting machine is not complete, the coolant splashes around with the movement of the electrode wire during processing, and cannot enter the cutting seam. The electrode wire cannot be fully cooled, which can easily cause the electrode wire to be burned off. Therefore, it is necessary to check whether the intermediate wire cooling system is complete before intermediate wire cutting.

3. The degree of tightness of the middle wire molybdenum wire. If the installation of the molybdenum wire is too loose, the molybdenum wire will shake severely, which will not only cause wire breakage, but also directly affect the surface roughness of the workpiece due to the shaking of the molybdenum wire. But the molybdenum wire cannot be installed too tightly, as excessive internal stress can also cause wire breakage. Therefore, during the cutting process, the tightness of the molybdenum wire should be appropriate. Newly installed molybdenum wire should be tightened before processing, and the force should not be too strong when tightening the wire.

4. Intermediate wire transport mechanism. The wire transport mechanism of a medium wire cutting machine is mainly composed of a wire storage cylinder, a wire frame, and a guide wheel. When the accuracy of the wire transport mechanism decreases (mainly in the transmission bearings), it will cause radial runout and axial displacement of the wire storage drum. The radial runout of the wire storage tube will reduce the tension of the electrode wire, causing it to loosen, and in severe cases, it may cause the molybdenum wire to detach and break from the guide wheel groove. The axial movement of the wire storage cylinder can cause uneven wire discharge and result in wire stacking. The shaft and bearings of the wire storage tube often have gaps due to wear, which can also cause wire shaking and breakage. Therefore, it is necessary to replace the worn shaft and bearings in a timely manner. So it is necessary to regularly check the accuracy of the wire transport mechanism and replace easily worn parts in a timely manner during the use of the intermediate wire feeding machine.

5. Improper selection of electrical parameters is also an important cause of wire breakage. So it is necessary to choose reasonable electrical parameters based on the thickness of the workpiece, and to widen the pulse interval to facilitate the discharge of molten metal particles. At the same time, the peak current and no-load voltage should not be too high, otherwise it will increase the energy of a single pulse, accelerate the cutting speed, and easily generate concentrated discharge and arc, causing wire breakage.

Based on the above, we can identify the causes of wire breakage in wire cutting processing. By starting from the causes, we can fundamentally solve the problem of wire breakage in wire cutting processing. For more information about wire cutting problems, you can consult SanYe Wire Cutting Wang Sheng: 13922985987 SanYe Wire Cutting Service Hotline: 0769-85415566, SanYe Wire Cutting After sales Service Hotline: 0769-85548566. SanYe Wire Cutting welcomes your consultation.