Wire-cut EDM Machine Broke Wire - Causes & Solutions
Wire-cut EDM (Electrical Discharge Machining) is an electrical process which uses a high voltage power supply to make arc between a targeted metal and a cutting wire which melts and cuts it. EDM is an effective technique for harder or tougher than conventional cutting materials. However, when going through a process of wire-cutting EDM, wire breaking is a common problem which needs to be taken into consideration.
Causes of wire breaking:
1. Excessive pressure: Applied pressure to the cutting wire exceeds the required maximum amount in the cutting process. This can cause the wire to break due to being over-stretched and pressures build-up at a range of weak points.
2. Incorrect wire tension: Cutting wire tension when doing the EDM process also needs to be in proper tension to allow the wire to feed normally and ensure wire continuity. Too much of wire tension can cause wire snap, while too less of tension can cause wire sagging which will also cause breaking.
3. Poor wire diameters and other flaws: Sub-standard wire diameters are prone to be tight and brittle, while having an uneven surface which can cause even more chances for the wire to snap.
4. Dirt accumulate inside the flushing tube: When the flushing tube is blocked by dirt, it can reduce the flushing effect, which can cause wire breaking.
Solutions:
1. Adjust the pressure and tension: Keep the pressure and tension of the wire to within the safety range recommended by the machine supplier.
2. Improve the cutting wire quality: Make sure that the cutting wire is of good quality and free from any obvious flaws.
3. Check the flushing tube regularly: Make sure the flushing tube is clean and free from any blockage by inspecting it regularly and cleaning it often.
4. Keep the EDM functioning parts in good condition: Regularly inspect and maintain the EDM cutting components to ensure all the functioning parts are working properly, and to reduce the chances of any unforeseen accidents.
Wire breaking is a common issue when doing wire-cut EDM. But with proper maintenance and attention to details, it is still possible to prevent them from happening. By understanding the causes and finding solutions, the chances of wire breaking can be greatly reduced, ensuring smooth and efficient EDM wire cutting process.
