WEDM machining error is the difference between the finished workpiece and the desired value at the end of the cutting process. This gap may come from the machine precision, may come from the material deformation, may come from the calculation of the error, may also come from the machine calculation of the control error, clear cause is possible to eliminate the error.
1. Calculation errors: This is a human cause, it is possible to verify the calculation, can be proved, but also can be found early. Intermediate calculation of premature rounding, repeatedly using an irrational number with insufficient digits (such as when multi-tooth shape), decimal angle system and degree minutes and seconds system confusion, etc.
2. machine control errors: the frequency of occurrence is less, because today's machine control system is tried and tested, technically mature. Man-made errors it will refuse to accept, it accepts down can also be calibrated before processing or back to zero check. The error accumulated due to multiple rotational translation back to zero check can also be found.
3. The accuracy of the machine tool: this usually refers to mechanical accuracy, is the actual value and the theoretical value of that difference. The more direct reason for this difference is the return difference and straightness, perpendicularity. The range of this difference should be within 0.005 to 0.02mm, this value can be measured, can be adjusted, on today's machine structure, to make this error value control below 0.02 is very easy, and to 0.005 below is very difficult.
4. Material deformation: As long as there are good operating habits, after the calculation to rehearse, after the input to check, before starting to zero, the handwheel scale to check. They did not miscalculate, the machine did not go wrong should have sufficient certainty, all that remains is the deformation, only the causes of deformation and ways to overcome it to carefully figure out
What will lead to large errors in the cutting shape of wire cutting? Cause analysis.
1. In cutting the corner due to the hysteresis of the electrode wire, will cause the corner collapse; for the corner requirements of high precision workpiece, should be selected with the parameters of the corner strategy
2. To reduce the deformation during the processing of larger workpieces, the processing process can be improved from.
(1). Concave die: make two main cuts, first increase the compensation amount of the main cut by 0.1mm-0.2mm on one side for its primary main cut, let its stress release, and then use the standard offset for its secondary main cut.
(2). Convex die.
1. Two or more tentative allowances should be left for open machining during programming.
2. Arrange reasonable starting cut position and support position. Try to punch holes and avoid cutting directly from the outside of the material.
3. Wire is not vertical: re-perform wire correction.
4. The external environment of wire cutting machine tool is poor and vibrating: improve the external environment of machine tool.
5. Electrode wire, workpiece material quality problems: recommend the use of original supplies, no quality problems with the material
6. The workpiece clamping position and the upper and lower nozzle distance is too large: adjust the clamping method.
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