So complete! Common problems and countermeasures in WEDM processing

01 Broken wire

1) The discharge state is not good

Countermeasure: reduce the P value, this operation will reduce the processing efficiency



2) The upper and lower water nozzles cannot be veneered

Countermeasure: reduce the P value, and check whether the upper and lower water nozzles are damaged, if damaged, please replace it in time



3) The conductive block is severely worn or too dirty

Countermeasure: Clean, rotate or replace the conductive block



4) The guide wire is too dirty, causing the wire to be scraped

Countermeasure: Clean the guide wire parts



5) Too much tension

Countermeasure: Reduce the wire tension, especially when cutting the taper



6) Quality problems of electrode wire and workpiece material

Countermeasures: replace the electrode wire; reduce the P and I values until the wire stops



7) The waste wire in the waste wire barrel overflows and contacts the machine tool or the ground, causing a short circuit

Countermeasure: put the overflowing waste wire back into the waste wire bucket and clean up the waste wire bucket in time



8) Insufficient cooling water for conductive block

Countermeasure: Clean the cooling water circuit



9) The wire is pulled and broken, and it is broken at the wire take-up wheel

Countermeasure: Check the wire pressing ratio of the wire take-up wheel, the standard value is 1:1.5~1.6; check the bearing of the lower guide wheel



10) The wire is not running smoothly, and the balance wheel shakes greatly

Countermeasure: Correct wire speed, tension

02 Low processing efficiency

1) Not veneer processing, reducing P and I values

Countermeasure: Adjust the Z axis and try to veneer processing



2) The process sequence file is incorrect

Countermeasure: According to the processing requirements, select a reasonable process sequence file



3) The workpiece is deformed, and the trimming does not move

Countermeasures: Reasonably arrange the process to reduce material deformation



4) ACO adaptive function is selected

Countermeasure: When the cutting state is stable, ACO can be cancelled



5) There are many corners, and the corner strategy is used

Countermeasure: Appropriately reduce the corner strategy



6) Repair the mold, the main cutting speed is not limited, and the repair speed is slow

Countermeasure: When repairing the mold, set a reasonable speed limit value for the main cutting to avoid the speed is too fast and the margin is not cut in place



7) The main cutting efficiency is lower than before

Countermeasure: Maintain and maintain the machine in time

03 Silk marks on the surface

1) The workpiece material is deformed, or there are impurities inside

Countermeasure: Arrange the process reasonably, or replace the material



2) The guide wire is too dirty, and the conductive block is seriously worn

Countermeasure: Maintain and maintain the machine in time



3) The flushing state is not good

Countermeasure: Check the upper and lower water nozzles, if there is any damage, even replace the new water nozzles



4) The working fluid is too dirty

Countermeasures: clean the tank and water tank, replace the working fluid



5) Insufficient cooling water for conductive block

Countermeasure: Clean the cooling water circuit



6) The wire is not running smoothly, and the balance wheel shakes greatly

Countermeasure: Correct wire speed, tension



7) Trim short-circuit fallback

Countermeasure: Adjust and increase UHP



8) Vibration near the machine

Countermeasure: Improve the external environment of the machine tool



9) The liquid temperature is too high or the temperature difference between room temperature is large

Countermeasure: Use a refrigerator to control the liquid temperature and ensure room temperature

04 The workpiece is concave and bulging, the size of the head

1) The center of the workpiece is concave

Countermeasure: reduce the Ssoll value of the main cutting and trimming parameters



2) The belly is bulging in the middle of the workpiece

Countermeasure: Increase the Ssoll value of the main cutting and trimming parameters



3) Straight body workpiece size head

Method 1: Add taper compensation

Method 2: Adjust CCON (based on the main program plane J, adjust the size of the reference plane)

05 Silk marks at the feed of the die

Method 1: Use the arc cut-in-arc cut-out method



Method 2: Use the cut-in-cut-out point separation method. When programming, set each feed point at a different position to avoid feeding and retracting from the same point

06 Wire hole short circuit

Method 1: Reduce the electrode wire tension and flushing pressure 2. After normal discharge, gradually change back to the original parameters



Method 2: Move the XY axis to the non-short-circuit position, input CTA, P, X_, Y_ (the coordinates of the short-circuit point), execute the key to discharge manually, and return to the pause point to re-execute the discharge machining