How to improve the efficiency of wire cutting

2022-06-22
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How to improve the efficiency of wire cutting

wire cutting efficiency is mainly affected by two factors: one is the current carrying capacity (current) of the wire, and the other is that the etchings in the cutting seam cannot be removed in time. The pulse energy is consumed by the coherent electrical interaction between the wire cutting and the general public. Many typical tests have been conducted in the industry on the cutting efficiency of molybdenum material fast wire walking machine tools. The results show that when the current carrying capacity of molybdenum wire reaches 150a/mm2, its tensile strength will be reduced to 1/3~1/4 of the original strength. This current value is regarded as the limit of molybdenum wire current carrying for cutting, such as Ф 0.12 current carrying 1.74a, Ф 0.15 current carrying 2.65a, Ф When the current carrying capacity is 3.82a, the limit value of cutting molybdenum wire is reached. If the current carrying capacity is increased, the service life of molybdenum wire will be shortened. DX-1 coolant from Beijing grease chemical plant, with different thicknesses such as Ф 0.12mm and Ф With 0.15mm molybdenum wire and 50mm thick ordinary steel, the area cutting efficiency at the maximum current carrying capacity is 70.43mm2/min and 90.41mm2/min respectively. It shows that the current carrying capacity can be increased when the diameter of molybdenum wire is thickened, and the efficiency can be improved when the current is large. However, it is not advisable to increase the current by increasing the thick wire. The wire diameter cannot be increased to more than 0.23mm for wire cutting with fast wire walking. This is because the discharge speed of the etched material is limited. When the current increases to the average value of 8a, there will be short circuit or electric arc discharge in the gap, and the barely maintained short-time spark discharge will also sharply increase the loss of molybdenum wire. When the cutting material is thickened and it is more difficult to discharge the etched material, the energy loss is more, and the effective processing pulse is less. The discharge current becomes a linear load current, heating the molybdenum wire. This is the main reason for the loss of energy and wire breakage. The high pollution control cost

in view of the two main reasons affecting the processing efficiency, corresponding efforts should be made in the following aspects to improve the processing speed:

① increase the energy of a single pulse, i.e. pulse amplitude and peak current. In order not to overburden the wire's current carrying capacity, the pulse interval should be increased accordingly so that the average current value does not increase too much

② maintain the dielectric coefficient and insulation strength of the coolant, and use wood fiber to maintain high spark explosion force and cleaning ability, so as to minimize the short-circuit effect of the etchings on the pulse

③ improve the mechanical accuracy of the wire conveying guide system, because the narrow seam always travels faster than the wide seam, and the straight seam always travels faster than the folded seam

④ properly increase the wire speed, so that the water speed brought into the gap by molybdenum wire is accelerated, the water volume is increased, and the eroded substances are discharged more effectively

⑤ increase the envelope of water to the wire outside the gap, that is, let the water accelerate under the driving of the wire. The accelerating water has a strong cleaning effect on the gap

⑥ improve frequency conversion tracking sensitivity and increase pulse utilization

⑦ reduce the reversing time of the wire feeding motor, start faster and increase the effective processing time

through the above efforts, it is possible to improve the wire cutting efficiency to 100~120mm2/min

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