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In CNC wire cut, workpiece deformation is a common and significant issue. This article will explore the reasons for workpiece deformation during wire cutting and how to effectively avoid it to ensure machining accuracy.
The root cause of deformation in CNC wire cut is closely related to changes in internal stress within the material. Similar to splitting a bamboo stick in half, both halves will bend due to stress imbalance. During wire cutting, the workpiece's stress balance is also disrupted, leading to deformation during the cutting process.
Specifically, the following factors may cause workpiece deformation in CNC wire cut:
Material stress: The material might have internal stress before machining, which will redistribute during cutting, causing deformation.
Workpiece structure: The shape and size of the workpiece greatly influence deformation. Workpieces that are long and narrow or have thinner walls are more prone to deformation.
Machining method: The choice of cutting path, clamping method of the workpiece, and machining sequence also affect the deformation scenario.
These factors work together, making the issue of workpiece deformation in CNC wire cut significant. Particularly, when deformation exceeds machining accuracy requirements, the workpiece's dimensions and shape are affected.
To reduce the risk of workpiece deformation in CNC wire cut, the following measures can be taken to control and optimize the machining process:
Pre-treatment by rough machining: Before conducting CNC wire cut, performing rough machining or stress-relieving cuts is an effective preventive measure. By removing most of the material first, the impact of internal stress on the final cut can be reduced. For example, for large concave molds, a primary cut can be done first to release internal stress, followed by a standard main cut to effectively reduce deformation.
Machining through holes: When cutting punch dies, cutting directly from the material's edge can cause stress imbalance and lead to deformation. By machining through holes in the material, cutting can be done within the closed contour, thus reducing deformation.
Optimizing cutting path: Reasonable arrangement of the cutting path is key to avoiding deformation. It is recommended to place the cutting initiation point near the clamping end, avoiding excessive stress in segments where the workpiece separates from the clamp, to reduce deformation caused by improper path arrangement.
Multiple cuts: For some workpieces, despite other measures, deformation may still occur. In this case, multiple cutting methods can be used to improve machining accuracy. Fast wire cutting with multiple passes can effectively improve surface roughness and reduce deformation caused by stress issues.
Multi-hole concave die processing: For templates requiring high precision, multiple cuts and gradual trimming can reduce deformation. The first cut removes all waste from the holes, followed by individual trimming of each hole, which effectively releases internal stress, ensuring the final machining dimensional accuracy.
Setting multiple segments of temporary stock: For large, complex workpieces, setting multiple cutting initiation points and temporary stock in the programming stage helps reduce deformation. By segmenting the workpiece into multiple parts for cutting, deformation caused by the workpiece's complex shape can be minimized.
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