The parameters for medium-speed wire cutting machine include pulse width, pulse interval, power, and wire feed speed. These parameters are adjusted based on different cutting stages and material properties to ensure processing quality and efficiency.
1. Pulse Width and Pulse Interval
Pulse Width (PW): defines the duration of the discharge time, impacting cutting speed and surface roughness.
Pulse Interval (PI): the time interval between two discharges, affecting cutting stability and electrode wire lifespan.
2. Power
Power: determines the magnitude of the discharge energy, influencing cutting speed and material removal rate.
3. Wire Feed Speed
Wire Feed Speed: divided into roughing and finishing stages; high-speed wire feed (8-12mm/s) is used during roughing while low-speed wire feed (1-3mm/s) is employed during finishing to minimize material deformation and electrode wire wear.
4. Cutting Stages and Parameter Adjustments
First Cut: high-speed stable cutting using high peak current and longer pulse width for high-current cutting to achieve higher cutting speeds.
Second Cut: precision machining to ensure dimensional accuracy; medium specifications are utilized to achieve a surface roughness Ra of 1.4~1.7μm after the second cut.
Subsequent Cuts: polishing with minimum pulse width and maximum pulse interval; wire feed speed is set at 1-2m/s.
5. Special Material Processing
For special materials such as high-strength, high-hardness, or highly ductile mold materials, adjustments in cutting parameters are necessary to accommodate material characteristics while minimizing processing deformations.
6. Coolant Usage
Coolant serves to remove chips and eliminate ions during the cutting process; maintaining a consistent cutting current along with steady feeding speed is crucial in meeting workpiece dimensional requirements.
By appropriately configuring these parameters, it is possible to optimize the processing procedure for medium-speed wire-cutting operations—enhancing both processing quality as well as efficiency while extending electrode wire longevity.
