Pendant Lamp: Wire EDM Machine Problem Solution

1. Low Cutting Speed/Low processing efficiency
1) the initial discharge of low processing efficiency ----- electrode size scaling amount (spark-bit) to a large, automatic programming can choose a larger number of current conditions. To the extent possible pre cavity milling.
2) low discharge machining stage efficiency program in the middle of each segment condition ----- margin between too much can also be reduced allowance between two segments.
3) low application efficiency ----- final paragraphs EDM machining using the timer function to effectively control the finishing time (need to set the processing time).
4) the area is too small ----- system input area limitation threshold, even if the amount of scaling electrode size is bigger, because the area is too small, it does not produce large discharge conditions. Such cases can be appropriately increase the area of human values entered.
5) the incorrect application type ----- choose such a large cavity is actually processed and the choice of the "standard" type of application. All application types "microfabrication" the least efficient.
6) processing priority ----- Choose low loss priority is low efficiency, choose a high priority is speed and efficiency, the loss is too large.
7) discharge, carrying the knife combination unreasonable ----- according to the processing status, carrying knives to adjust the height, the discharge time match.
8) ----- optimization parameters decrease pulse interval P, to increase the servo reference COMP.

9) the use of improved technology ----- graphite electrodes, greatly enhance the overall productivity

Height Cutting Spark Discharge

2. Big electrode wear
1) ----- improper use parameters should be used as a low loss priority processing parameters. Small electrodes can choose the type of micro-machining applications.
2) discharge condition number is too small electrode tip ----- For, you can not use a large current process.
3) discharge energy is too small, resulting in inefficient processing time of discharge electrodes and electrode loss ----- if accompanied by a large loss when the processing speed is too slow, increase processing efficiency.
4) the electrode material is not good ----- use high purity copper, or even lower loss Luoyang Copper is a copper tungsten alloy as the electrode material.
5) increasing the pulse width is too small ----- condition number of the pulse width T, can significantly reduce electrode wear.
6) ----- low-loss pulse waveform, a tapered discharge waveform pattern (Mode10)

3. points in the inaccurate position deviation
1) using conventional methods, "the electrodes touch points in the workpiece", because points belonging to surface contact between the electrode and the presence of a number of factors will affect the points in the workpiece accuracy ----- recommended "base ball-point divide in "positioning method. Work bench fixed a benchmark ball as a reference, prior to processing in the spindle head clamping a benchmark ball points on the workpiece, and then on the workbench reference points in the ball, so you get a distance relationship, after all the reference electrode are points in the ball.
2) the electrode and the workpiece datum accuracy, ensure the accuracy of debris ---- electrode and the workpiece datum, and wipe clean.
3) perception of speed is not too fast (Set F: 75mm / min)
4) Use precise clamping and positioning system.

4.The machined surface roughnesss
1) electrode material is not good, there are impurities ----- high purity copper or copper Luo.
2) translational inappropriate choice ----- Use DOWN / ORB translational, and finishing process using a timed section.
3) improper spark oil, spark oil viscosity big spark ----- finishing oil suitable replacement.
----- Appropriate parameters need to be optimized to reduce the discharge time TEROS, increasing the pulse interval P, reduce the servo reference COMP.
4) red liquid mode uneven ----- finishing punch was not additional local.
5) matte surface treatment ----- difficulty factor, and recommend process to VDI14, more sophisticated processing surface of its conditions are demanding.
6) surface effects ----- priority standard of priority is generally better than a low loss priority.

5. The mirror effect is not good
1) Some of the workpiece material can not achieve mirror finish effect, such as SKD11, Cr12MoV, DC53 (most metal stamping die steel) ----- recommend using a mirror finish steel, such as SKD61, S136,718HH, NAK80 etc., or correct understanding deviation .
2) processing area is too large, reach a uniform mirror effect ----- area larger than 25 square centimeters should use the mixed powder processing.
3) translation inappropriate choice ----- Use DOWN / ORB translational, finishing with a timed processing function.
4) processing area entered incorrect ----- enter the exact processing area, so that the system automatically set the timer.
5) ----- mirror finishing segment conditions according to the processing status, carrying knives to adjust the height, the discharge time, carrying the knife to match the speed, do not use the red liquid, the liquid flow to be small.
6) the beginning of the process, the discharge is unstable, often carrying knives
The system automatically detects, the impact of adaptive ----- shutdown condition numbers of some automatic protection function (ACC2 / ACC4), reduced sensitivity MS, or the discharge time and carrying knives height control is set in accordance with User settings (User / Fix), so lift the knife presented as a regular, controlled state. (Not recommended, often this instability is having a protective effect)
7) ----- optimize processing parameters to optimize the discharge time, carrying knives height, carrying knives rate, pulse gap servo reference.

6. Processing size failed
1) small size after processing ----- Typically, the size processed using an automatic programming will Shaopian small, which is more secure.
2) Electrode size tolerance ----- check the electrode size, which is the premise.
3) ----- high dimensional accuracy according to the machining conditions, pre-processing, the size of the measured and processed electrode size, adjust translational radius.

7. how to process multiple workpieces
A plurality of processing a plurality of workpieces How to use ----- workpiece relative parts function, each piece is set to a relative zero, each piece of the current machine coordinate value memory, the program can take any of these relative zero transfer In order to achieve continuous processing a plurality of workpieces, these artifacts should be set up in the same tray (Mag Pos set to the same value).

8. What are the main points of carbide EDM
1) When the automatic programming to choose carbide processing parameters.
2) If there are higher requirements for electrode wear, rough machining of positive polarity may be used to reduce the electrode loss (the default parameters of the machine are negative, in fact, using the negative impact of thermal processing parameters thin, die life the best, but the loss is large, a plurality of electrodes need to be replaced.)
3) the use of a copper tungsten electrode material, can significantly reduce electrode wear, reduce the number of electrodes.

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