How much do you know about the technical level of slow-moving wire processing machine tools?

How much do you know about the technical level of slow-moving wire processing machine tools?

Dongguan WONDER Industrial Co., Ltd. is a company specializing in plastic injection molding processing,Two-color plastic mold ,Single-color plastic molds, precision injection molds, etc. Professional manufacturer in the manufacturing field.The company owns18Years of experience in precision plastic mold manufacturing, the company has employeesMore than 100 people, the factory occupies more than 5000 Square meters with8station Mikron CNC Machining center, precisionSODICK Wire cutting machine and Charmilles Mirror spark machine, 3 Dimensional testing equipment and useEROWA Fixture system,Single and double color injection molding machine 30 station .The mold master with more than ten years of experience in mold manufacturing has been growing with the company. Today, our mold master will explain to you the technical level of various grades of slow-moving wire processing machine tools.
01Development status of slow-moving wire processing technology

1) Improved processing accuracy

Multi-cutting technology is the fundamental means to improve the processing accuracy and surface quality of the slow-moving wire.Generally, it is formed by cutting once, cutting twice to improve accuracy, and cutting more than three times to improve surface quality.

Due to the hysteresis of the electrode wire when cutting the corner, it will cause the corner to collapse.In order to improve the accuracy of corner cutting, more dynamic corner processing strategies have been adopted.Such as: automatic change of processing speed, automatic adjustment of water pressure, control of processing energy, etc.

The high-precision finishing circuit adopted by the advanced slow-moving wire processing machine tool is an effective technology to improve the straightness of the processed workpiece, which significantly improves the accuracy of thick parts processing; in order to carry out small fillets, narrow slits, narrow grooves and fine parts The micro-finishing, the top CNC low-speed wire EDM wire cutting machine tool can be used0.02~0.03 ㎜ electrode wire for cutting.

In order to ensure high-precision processing, the machine tool’s mechanical accuracy, pulse power accuracy, and servo control accuracy (including the control of mechanical movement, pulse parameters, wire feeding system and working fluid system) have reached a very high level.The water temperature cooling device is adopted to make the internal temperature of the machine tool the same as the water temperature, which reduces the thermal deformation of the machine tool; adopts closed-loop digital communication(直)The flow servo control system ensures excellent dynamic performance and high positioning accuracy. The machining accuracy can be controlled within a few microns, and precise positioning can be achieved.0.1μmEquivalent control; immersion processing is used to reduce the thermal deformation of the workpiece; motor servo, closed-loop electrode wire tension control; voltage-modulated tool setting power supply to achieve high-precision tool setting, and the tool setting accuracy can reach 0.002 ㎜, no damage to the workpiece, no matter whether it is wet or dry.

2) Surface quality is improving day by day

The advanced slow-moving wire processing machine adopts a non-anti-electrolysis pulse power supply with an average voltage of zero, and the damage of electrolysis has been reduced to a minimum.In addition, due to the improvement of the pulse power supply, high peak value and narrow pulse width (microsecond level) are generally used. Most of the materials are thrown out of the gas phase, which takes away a lot of heat. The surface temperature of the workpiece cannot rise, and the phenomenon of cracking is great Reduce; not only the processing efficiency is high, but also the surface quality is greatly improved.The use of electroless power supply for wire EDM can control the surface deterioration layer2μmthe following.The wear resistance of the cutting edge of cemented carbide die is no different from grinding, and even better than mechanical grinding. More and more parts are processed by cutting instead of grinding.

3) Improve processing efficiency

Due to the development of nanosecond high peak current pulse power supply technology and detection, control, and anti-interference technology, the processing efficiency of slow-moving wire processing machine tools is also continuously improving, and the highest processing efficiency of current advanced slow-moving wire processing machine tools can reach500㎜²/ Min.Technical improvement of the processing efficiency of larger thickness workpieces with practical significance, such as cutting300 ㎜Thick workpiece, the processing efficiency can reach170㎜² / Min.For the processing of workpieces with varying thickness, the thickness of the workpiece is automatically detected, and the processing parameters are automatically adjusted to prevent wire breakage and achieve the highest processing efficiency in this state.

In addition, the fast automatic threading technology introduced by the advanced slow-moving wire processing machine tool, the automatic threading time <15 sImprove the efficiency of processing operations; the introduced double wire automatic exchange technology can adopt0.20~0.02 ㎜The electrode wire automatically performs double-wire switching processing.Use thick wire for the first cut, the general wire diameter is0.25 ㎜, in order to improve the processing efficiency, and can be cut without core; then use filaments for trimming, generally 0.10 ㎜ fine wire, small rounded corners can be cut, and the accuracy can be improved, and the overall can be saved30%~50%Cutting time.

4) Development of automation, intelligence and informatization

In the processing process, in order to reduce human intervention and ensure that the expected process indicators are achieved, the automation, intelligence and informationization of slow-moving wire processing has achieved corresponding development.

The complete process expert system of the slow-moving wire processing machine tool gives a complete set of parameters according to the processing requirements.Not only includes commonly used electrode wire grades and corresponding workpiece materials, but also providesPCD,PCBNThe processing parameters of special materials can be generated according to whether the upper and lower nozzles are in contact with the workpiece, the distance between the upper and lower nozzles, whether it is refined in the slit or the open surface, and which processing strategy is the priority of accuracy, surface roughness and efficiency. The electric discharge expert system deals with random factors in cutting, and uses adaptive control strategies and automatic control in the process of cutting in, cutting out, section changes, heart cutting, near-edge cutting, large section high-speed cutting, etc. Function, get continuous silk stable and efficient processing.

The automatic non-hole detection function is also very practical. During automatic skipping processing, if the pre-hole is forgotten or the hole position is shifted, the machine tool will automatically move to the next pre-hole, which can prevent the machine from stopping during unmanned processing. When a short circuit occurs after the wire is threaded, it can automatically search for the location to eliminate the short circuit, which improves the reliability of continuous unmanned operation.
Machine toolCNCThe system is equipped with standardized mechanical interfaces to form an intelligent manufacturing system.3RSystem orEROWAThe manipulator of the system can easily realize the automatic exchange of workpieces (pallets). Equipped with expert system and electrode wire automatic exchange technology, it can automatically complete the entire processing process.

02The technical level of various grades of slow-moving wire processing machine tools

The slow-moving wire processing machine tools can be divided into four grades: top-grade, high-grade, mid-grade, and entry-level.Typical manufacturers producing slow-moving wire machine tools are SwitzerlandGFProcessing plan (formerly Agie Charmilles), Japan’s Makino, Japan’s West, Japan’s Mitsubishi, Japan’s Sodick, Japan’s FANUC, etc.

1) Top slow-moving wire processing machine

This kind of slow-moving wire processing machine represents the highest level at present, mainly made in Switzerland and Japan.The machining accuracy of this type of machine tool can be guaranteed within ±0.002 Within ㎜, the highest processing efficiency can reach400~500㎜²/ Min, The surface roughness can reachRa0.05μm, Has perfect processing surface quality, almost no deteriorating layer on the surface, can use Φ 0.02 ㎜The electrode wire is micro-finished, and most of the main machine has a heat balance system, and some machine tools use oil for cutting.This type of machine tool has complete functions and high degree of automation. It can directly complete the precision machining of the mold, and the service life of the processed mold has reached the level of mechanical grinding.

2) High-grade slow-moving wire processing machine tool

This type of machine tool is basically produced by Swiss and Japanese companies, with automatic threading function, non-resistance anti-electrolysis power supply, overall thermal constant system, and can adopt Φ0.07 ㎜The electrode wire is cut, the accuracy is ±0.003 ㎜, the highest processing efficiency can reach300㎜²/ MinAbove, the surface roughness can reachRa<0.2μ m, It has the functions of timely detection of changes in the cross-section of the workpiece and real-time optimization of the discharge power.This type of machine tool is also widely used in precision stamping die processing.

3) Mid-range slow-moving wire processing machine

This machine tool is generally produced by Swiss and Japanese companies in China’s manufacturing plants. Some Taiwanese machines can reach this level of technical level, and their configuration and performance meet the requirements of most domestic precision wire-cutting processing.Generally, non-resistance anti-electrolysis power supply is used, which has the functions of water immersion processing and taper cutting.The highest practical processing efficiency is150~200 ㎜²/ Min, The best surface roughness reachesRa< 0.4μm, The cutting accuracy can reach ±0.005㎜, generally Φ0.1㎜ and above electrode wire for cutting, equipped with anti-collision protection system to avoid collision damage caused by programming errors or misoperation, equipped or optional automatic threading mechanism.

4) Entry-level slow-moving wire processing machine

This machine tool is generally a Taiwanese machine tool or a domestic machine developed and produced independently, and its configuration and performance meet the processing requirements of domestic ordinary molds and parts.Generally, the process of cutting one and repairing one and cutting one and repairing two is used to achieve stable surface finish.Ra0.8μmAbout, the processing accuracy is ±0.008㎜, most of them can only be used0.15 mmThe electrode wire of and above is cut, and the processed surface microstructure and corners have a certain gap with advanced machine tools.

Well, the mold master has also said so many important points. How much do you know about the technical level of the slow-moving wire processing machine?The plastic mold industry is a basic industry in the national economy, specifically involving machinery, automobiles, light industry, electronics, chemicals, metallurgy, building materials and other industries, with a wide range of applications.The rapid development of my country’s industry, including the development of automobile manufacturing, IT manufacturing and medical equipment, has ushered in development opportunities for the entire mold industry.

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