How to Upload Cut Conditions Wire Edm

one. W ire  Cleaved

(i) Poor discharge state—–lower the value of P. If the value of this value is profoundly reduced and the wire is still broken, consider reducing the value of I until the wire is continuous. This operation volition reduce the processing efficiency. If the wire breaks frequently, please refer to the following to find out the cause of the wire breakage.

(ii) The flushing state is non proficient, such as the upper and lower nozzles cannot exist veneered or open-ended processing. Unremarkably the cleaved wire is in the processing area — lower the P value, and check whether the upper and lower nozzle caps are damaged, if damaged, please supercede it.

(3) The conductive block is severely worn or also dirty. Usually, the location of the cleaved wire is well-nigh the conductive block—rotate or supersede the conductive block and make clean it.

(four) The guide wire part is also dirty, causing the wire to be scraped. Usually the cleaved wire is located near the guide wire part — make clean the guide wire parts.

(5) The wire tension is also loftier—–lower the wire tension FW in the parameters, especially when cutting with a taper.

(six) The type of electrode wire and the quality of the workpiece material —–supervene upon the electrode wire; reduce the P and I values until the wire is continuous.

(vii) The wire in the waste wire saucepan overflows, causing a brusk circuit. Usually, the wire will exist broken right after the processing is started-the waste wire in contact with the ground is returned to the waste product wire bucket to eliminate the short excursion.

(viii) When trimming the cut wire, the showtime may be inappropriate, causing the trimming to be immovable and breaking the wire-reduce the margin betwixt the offsets.

(ix) Broken wire at the rear take-up wheel—cheque the wire pressure level ratio of the take-up cycle, the standard value is 1:i.5.

(10) The cooling water of the conductive block is insufficient, ordinarily the cleaved wire is located near the conductive cake-check the cooling water circuit.

(11) The electrical conductivity of deionized water is too high. Usually the broken wire is in the processing area. If it exceeds the standard value of 10μs, the deionized water is recycled to the standard value or less than the standard value before processing. If the standard value is still not reached , Delight supplant the resin.

(12) The quality of deionized water is poor. Usually the broken wire is in the processing area-the water in the water tank has turbidity or peculiar smell. Delight supplant the filter paper core and water.

(13) The wire is broken, there is waste wire embedded in the lower ceramic guide wheel of the lower arm or the operation is not flexible-clean and re-adjust and install the ceramic guide bicycle, if necessary, check the wear of the guide wire nozzle and supervene upon it.

(14) Excessive vibration of the tension wheel (unsteady wire send) — Use a tension meter to correct the wire tension.

2. Processing Speed Problem

(1) Not according to the standard process, the upper and lower nozzles are more than 0.1mm abroad from the workpiece —– as far equally possible veneer processing.

(2) The created TEC file is wrong—–input the relevant procedure data correctly to obtain the correct TEC file.

(iii) Change the processing parameters, especially if the values of P and I are reduced besides much, the processing speed will be greatly reduced. Reasonable modification is required.

(four) The flushing state is not good, and the standard flushing pressure is non up to the standard. If the veneer processing is indeed not possible, the processing speed must exist correctly understood.

(5) Deformation of the workpiece leads to unstable discharge land during machining, especially trimming-control deformation.

(6) If ACO (Automatically Optimize Free energy) is checked in the parameter, in some cases, the processing efficiency will be reduced a lot. In the case of stable cutting, the ACO function can be unchecked.

(7) For workpieces with many corners, high precision can be obtained by using high-precision parameters. The main cutting default str is 55, but information technology will reduce efficiency-reduce the value of corner strategy str (such as 33) or abolish (Ready to 0) to increment the processing speed.

(8) The trimming speed is slow-the relative processing volume of each cut tin can be reduced a bit. If the trimming speed is increased, the start of the chief cutting can exist reduced by 0.01 mm-0.02 mm.

(nine) It is necessary to check whether the cooling water of the conductive cake is normal, especially whether the cooling h2o of the lower conductive block is nowadays.

(10) The main cutting efficiency is lower than earlier-please consider cleaning the lower guide wire core seat.

3. Surface Line Problems

(1) There is a trouble with the quality of the electrode wire-it is recommended to supersede it with a brand electrode wire.

(2) The problem of the blazon of workpiece material, or the workpiece contains impurities-supercede the workpiece material.

(iii) The release of local internal stress in the internal organization of the workpiece will cause wire marks to occur in individual positions of the workpiece.

(4) The temperature of the working fluid is besides loftier or the temperature change is too large-a fridge must be used to control the temperature of the fluid and ensure a suitable ambient temperature.

(5) The external surroundings of the automobile tool is harsh and the vibration is large—improve the external surroundings.

(vi) The conductive block is severely worn—–rotate or replace.

(seven) Insufficient cooling water for upper and lower conductive blocks-cleaning related parts.

(8) The guide wire part is too muddied-cleaning.

(ix) The working fluid is likewise muddied-make clean the tank and working surface area, and replace the working fluid.

(x) Observe whether the discharge country is stable and whether there is a short-circuit back-off phenomenon during trimming—–If necessary, the UHP value tin can be increased by ane~ii.

(xi) If the fringe is darker-you can change the trimming parameter Smode to 10 and increase the UHP value by 2.

(12) If the belch electric current and voltage are normal during trimming, but the speed is very low-the relative offset can be reduced.

(xiii) The flushing land is non expert, and the standard flushing pressure and jet shape are not upwards to standard-bank check whether the upper and lower nozzles are damaged.

(14) Unsteady wire tension—–calibrate wire speed and tension if necessary.

iv. The Surface Of The Workpiece Is Not Polished

(1) The relative showtime is besides modest—–appropriately increment the relative offset.

(2) The deformation of the workpiece leads to uneven cutting speed during trimming-command the deformation.

(three) The quality of the electrode wire is poor-it is recommended to replace it with a brand electrode wire.

(iv) The guide wire part is too dingy—–clean.

(5) The conductive block is severely worn—–rotate or replace.

(6) Wrong selection of process parameters—–select the correct TEC.

(seven) The flushing country is not good, and the standard flushing pressure level and jet shape cannot be reached —check whether the upper and lower nozzles are damaged.

(eight) Unsteady wire ship—bank check and suit.

5. Large Cut Shape Error

(1) The hysteresis of the electrode wire when cutting corners will crusade corners to collapse. For workpieces that crave high corner accuracy, TEC parameters with corner strategies should be selected.

(2) In order to foreclose deformation of large parts, the processing technology tin be improved —–

• ane) Die: Make two master cuts, showtime increase the kickoff of the main cut by 0.i—0.2mm on ane side, perform the kickoff master cut to release the stress, and so use the standard offset for the second main cut cut.
• 2) Punch: 2 or more than temporary stays should exist left, and it is processed by opening the shape during programming.
• 3) Appropriate starting position and supporting position; try to perforate as a threading hole.

(3) The wire alignment is not proficient—the wire alignment is performed over again.

(4) The external environment of the machine tool is harsh and the vibration is large—amend the external environment.

(five) The type of electrode wire and the quality of the workpiece fabric are likewise poor—select the advisable electrode wire and workpiece.

(6) The distance between the clamping position of the workpiece and the upper and lower nozzles is too large — adjust the clamping method.

(7) The wire speed or wire tension is abnormal — adjust or calibrate.

(8) The flushing conditions have changed significantly, causing the filament to vibrate profoundly. The possible cause is that the upper and lower nozzles are damaged — please replace if damaged;

(9) Whether the axis and upper and lower artillery of the machine tool collide, causing the mechanical accuracy of the machine tool to change.

half-dozen. The Workpiece Is Concave Or Convex

(one) Optimize parameters—–In the case of concave, the Ssoll value of the main cutting and trimming process parameters can be reduced, the wire speed and tension can be increased, the last cut abiding speed cut speed can be increased, and the interval betwixt trim 1 and the main cut can be increased The relative outset.

(two) The processing method when convex is contrary to that of concave.

7. Taper Mistake Of Straight Workpiece

(one) The quality of the electrode wire is poor-information technology is recommended to replace it with a make electrode wire.

(ii) Optimize the parameters—–Increase the wire speed and slightly increment the wire tension.

(3) Appropriate taper compensation is added to ISO program —–Use taper compensation function during programming.

(four) Arrange the upper and lower low pressure water flow rate—–correctly arrange the low pressure level flushing liquid flow charge per unit when trimming.

eight. Traces Of The Feed Line

When machining concave molds, dents often appear at the cutting edge. For some precision molds, the precision and surface requirements are very high. The dents on the surface of the workpiece straight touch on the surface quality of the product.

• It can be improved by adopting the method of arc in and arc out to advance and retract. When programming, enter the arc cut-in radius and exit radius,four-0.5 is OK.
• In the automatically generated program, the lawmaking for introducing the outset of cutting and exiting cutting is H000, and the default value is 0. Therefore, the entry and go out are at the same betoken, forming a secondary discharge, resulting in a dent of a few microns . It can avoid this phenomenon by adopting the oblique accelerate and oblique retreat to stagger the entry and exit points. You only need to assign the value of H000 in the programme, generally 0.03-0.06.

ix. Frequent Wire Breakage During Edge Finding

Please check if the wire is frequently broken when using 0.15mm or 0.1mm electrode wire to notice the edge:

The wire tension in the machine configuration is incorrect—–The system defaults to set the border-finding tension to 12. If you lot change to 0.15mm or 0.1mm electrode wire, you must reduce this tension value, otherwise information technology will be in the procedure of wire alignment. Wire breakage volition occur.

The FW of 0.1mm wire electrode is adjusted to iii; the FW of 0.15mm wire electrode is adjusted to vii.

10. The Arc and Arc Connection Mistake Alarm

Because some mold drawing files are UG, Master CAM and other 3D software are converted to 2D drawings, some corners, arcs and actual dimensions of the converted second drawings are incorrect, and the accuracy of the programming software is continued. After the plan is completed, the simulation processing is simulated. Sometimes it will alarm that the arc and the arc are continued incorrectly.

(one) Increase or subtract the arc I or J value in the alarm program line by 0.001.

(ii) When using Fikus programming software, you can modify the subsequent processing configuration file from the original three decimal places to four decimal places. The specific steps are:

• 1) Detect the Metalcam folder of the Fikus installation file, double-click to find the Fikusvisualcam folder.
• ii) Find the post folder, double-click to find the cfg folder.
• iii) Observe the post-processing file edmAGIE-CA Frontier-G61.cfg.
• 4) Change iii in item five to 4

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Source: https://www.sansmachining.com/wire-edm-processing-problems-and-solutions-101/