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CNC EDM wire cuts are high-precision processing equipment, widely used in mold manufacturing and difficult parts processing. Mastering its processing steps can not only ensure the quality of the workpieces but also enhance production efficiency. This article will detail the main steps of CNC EDM wire cut processing.
Before CNC EDM wire cut processing, drawing analysis and review are the crucial first steps. Through a careful examination of the drawings, it can be determined whether it is suitable to use the EDM wire cut machine for processing. Mainly, attention should be paid to the following points:
Surface roughness and dimensional accuracy: If the drawing requires high surface roughness or strict dimensional accuracy, the EDM wire cut machine may find it difficult to meet these requirements.
Gap size: If the narrow gap of the workpiece is smaller than the diameter of the electrode wire plus the discharge gap, or if the corners of the pattern require no fillets, then such workpieces are not suitable for processing with the EDM wire cut machine.
Material conductivity: EDM wire cut machines can only process conductive materials; non-conductive materials such as plastics and ceramics cannot be handled.
Workpiece thickness and size: If the thickness of the workpiece exceeds the span of the wire rack or the processing length exceeds the XY table's effective travel, special handling may be required.
Under these processing conditions, it is necessary to carefully consider factors such as the workpiece's surface roughness, dimensional accuracy, thickness, material type, and size to ensure processing quality.
When performing CNC EDM Wire Cut processing, programming and parameter setting are critical steps that determine the processing outcome. Here are some key points to note during programming:
Punching die clearance and transition radius: Proper determination of punching die clearance is crucial for the mold's service life. Generally, the punching die clearance for soft materials is chosen to range within 10% —15% of the material thickness, and for hard materials, 15% — 20%. Setting the transition radius is also necessary, as this helps improve the mold's service life and reduce burrs.
Writing the processing program: Based on the drawings and requirements of the workpiece, choose the appropriate clamping position, cutting start point, and cutting path. The cutting start point is usually chosen at the corners of the pattern or easily trimmed parts. The cutting path should be designed to minimize mold deformation, ensuring a smooth and efficient processing process.
Making and proofreading the program tape: After completing the program tape, it is necessary to proofread the program and tape contents line by line and input them into the controller after ensuring there are no errors. For high-demand molds, sample cutting is required to verify processing accuracy and clearance fit. If issues are found, the program needs to be adjusted in time to avoid workpiece scrapping.
CNC EDM Wire Cuts' actual processing process must strictly follow the prepared program.
Below are the key points for post-processing inspection:
Template inspection: Simple workpieces can be processed directly, but for high-precision molds, thin material sample cutting must be conducted to check accuracy and clearance fit. The program is adjusted based on the sample cutting results to ensure that the final processing effect meets the requirements.
Quality control: During the processing, closely monitor the actual state of the workpiece to ensure consistency between processing parameters and actual results. If there are inconsistencies, adjustments and optimizations are needed to ensure the final product's quality.
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