1. Broken wire problem
(1) Poor discharge status-----Reduce the P value. If the value decreases significantly and the wire is still broken, consider lowering the I value until no thread breaks. This operation will reduce the processing efficiency. If the wire breaks frequently, please refer to the following content to find out the real cause of the wire breakage.
(2) The flushing state is not good, such as the upper and lower nozzles cannot be processed, or when open processing. Usually the broken wire is located in the processing area ----- reduce the P value and check whether the upper and lower nozzle caps are damaged. If damaged, please replace it.
(3) The conductive block is seriously worn or too dirty. Usually the broken wire is located near the conductive block - rotate or replace the conductive block and clean it.
(4) The guide wire part is too dirty, causing scraping. Usually the broken wire is located near the guide wire part---clean the guide wire parts.
(5) The wire tension is too high-----lower the wire tension FW in the parameters, especially when cutting with taper.
(6) Problems with the type of electrode wire and the quality of the workpiece material - replace the electrode wire; reduce the P and I values ??until the wire stops.
(7) The wire in the waste wire barrel overflows, causing a short circuit. Usually the wire will break just after starting the processing -----Put the waste wire in contact with the ground back into the waste wire barrel to eliminate the short circuit.
(8) When trimming the cut wire, the offset may be inappropriate, causing the trimming to fail and the wire to break - reduce the margin between the offset.
(9) Broken wire at the rear take-up wheel-----Check the wire pressing ratio of the take-up wheel, the standard value is 1:1.5.
(10) The cooling water of the conductive block is insufficient, and the broken wire is usually located near the conductive block - check the cooling water circuit.
(11) The conductivity of deionized water is too high, and the broken wire is usually located in the processing area - if it exceeds the standard value for 10 seconds, circulate the deionized water to the standard value or less than the standard value. Reprocess; if it still cannot reach the standard value, please replace the resin.
(12) The quality of deionized water is poor, and the broken wire is usually located in the processing area-----the water in the water tank appears to be turbid or smelly, please replace the filter paper core and water.
(13) The wire is pulled off, and there is waste wire embedded in the lower ceramic guide wheel of the lower arm or the operation is not flexible-----Clean and re-install the ceramic guide wheel, and check the guide wire if necessary Nozzle wear condition and replace.
(14) The tension wheel shakes too much (the wire movement is unstable)---use a tensiometer to correct the wire tension.
2. Processing speed problem
(1) Not according to the standard process, the distance between the upper and lower nozzles to the workpiece is higher than 0.1mm ----- Process as close as possible.
(2) The created TEC file is incorrect-----Enter the relevant process data correctly to obtain the correct TEC file.
(3) The processing parameters have been modified, especially the P and I values ??have been reduced. Excessive values ??will cause the processing speed to be significantly reduced -----need to be modified reasonably.
(4) The flushing condition is not good and the standard flushing pressure cannot be reached-----If it is indeed impossible to process the veneer, you need to correctly understand the processing speed.
(5) The deformation of the workpiece leads to unstable discharge state during processing, especially trimming-----control deformation.
(6) If ACO (automatic energy optimization) is checked in the parameters, in some cases it will reduce the processing efficiency ----- When the cutting is stable, the check can be unchecked Select the ACO function.
(7) For workpieces with many corners, higher accuracy can be obtained by using high-precision parameters. The default str for main cutting is 55, but it will reduce efficiency ----- reduce the corner strategy str value ( If set to 33) or canceled (set to 0), the processing speed can be increased.
(8) The trimming speed is slow-----the relative processing amount of each knife can be changed a little smaller. If the trimming speed is increased, the offset of the main cut can be reduced by 0.01. ㎜-0.02㎜.
(9) It is necessary to check whether the cooling water of the conductive block is normal, especially whether there is cooling water in the lower conductive block.
(10) The cutting efficiency of the main cutter is lower than before - please consider cleaning the guide wire core seat.
3. Surface line problem
(1) There is a problem with the quality of the electrode wire ----- It is recommended to replace it with a branded electrode wire.
(2) There is a problem with the type of workpiece material, or the workpiece contains impurities-----replace the workpiece material.
(3) The release of local internal stress in the internal structure of the workpiece will cause line marks to occur in individual locations of the workpiece.
(4) The temperature of the working fluid is too high or the temperature changes too much - a refrigerator must be used to control the liquid temperature and ensure a suitable ambient temperature.
(5) The external environment of the machine tool is harsh and the vibration is large---improve the external environment.
(6) The conductive block is seriously worn-----rotate or replace.
(7) Insufficient cooling water for the upper and lower conductive blocks - clean related parts.
(8) The guide wire part is too dirty-----clean it.
(9) The working fluid is too dirty-----Clean the fluid tank and working area, and replace the working fluid.
(10) Observe whether the discharge state is stable and whether short-circuit regression occurs during trimming-----If necessary, the UHP value can be increased by 1~2.
(11) If the stripes are deeper ----- you can change the trimming parameter Smode to 10 and increase the UHP value by 2.
(12) If the discharge current and voltage are normal during trimming, but the speed is very low-----the relative offset can be reduced.
(13) The flushing condition is not good, and the standard flushing pressure and jet shape cannot be reached-----check whether the upper and lower nozzles are damaged.
(14) The wire tension is unstable-----calibrate the wire speed and tension if necessary.
4. The surface of the workpiece is not polished
(1) The relative offset is too small - increase the relative offset appropriately.
(2) The deformation of the workpiece causes uneven cutting speed during trimming ----- control the deformation.
(3) The quality of the electrode wire is poor-----it is recommended to replace it with a branded electrode wire.
(4) The guide wire part is too dirty - clean it.
(5) The conductive block is seriously worn-----rotate or replace.
(6) Wrong selection of process parameters-----choose the correct TEC.
(7) The flushing condition is not good and the standard flushing pressure and jet shape cannot be reached---check whether the upper and lower nozzles are damaged.
(8) The silk transport is not smooth---check and adjust.
5. Large cutting shape error
(1) The lag of the electrode wire when cutting corners will cause the corners to collapse ----- For workpieces that require high corner precision, TEC parameters with corner strategies should be selected.
(2) In order to prevent deformation in large-scale processing, the processing technology can be improved -----
1) Concave mold: Make two main cuts, first cut the main cut Increase the offset by 0.1 to 0.2mm on one side to perform the first main cut to allow the stress to be released, and then use the standard offset to perform the second main cut.
2) Punch: Two or more temporary allowances should be left, and the shape should be processed during programming.
3) Suitable cutting starting position and supporting position; try to perforate as a threading hole.
(3) The thread alignment is not good---re-do the thread alignment.
(4) The external environment of the machine tool is harsh and the vibration is large---improve the external environment.
(5) The type of electrode wire and the quality of the workpiece material are too poor---choose the appropriate electrode wire and workpiece.
(6) The distance between the workpiece clamping position and the upper and lower nozzles is too large---adjust the clamping method.
(7) The wire speed or wire tension is abnormal---adjust or calibrate.
(8) The flushing conditions have changed significantly, causing the wire to vibrate greatly. The possible reason is that the upper and lower nozzles are damaged---please replace them if damaged;
(9 ) Whether the axis of the machine tool and the upper and lower arms collide, causing the mechanical accuracy of the machine tool to change.
6. The workpiece is concave or convex
(1) Optimization parameters-----When the workpiece is concave, the process parameter Ssoll value of the main cutting and trimming can be reduced , increase the wire speed and tension, increase the constant speed cutting speed of the last knife, and increase the relative offset between trim 1 and the main cut.
(2) The processing method when the center is convex is opposite to that of the center concave.
7. Taper error of straight workpiece
(1) The quality of the electrode wire is poor ----- It is recommended to replace it with a branded electrode wire.
(2) Optimize parameters-----increase the wire speed and slightly increase the wire tension.
(3) Add appropriate taper compensation in the ISO program -----Use the taper compensation function when programming.
(4) Adjust the upper and lower low-pressure water flow - correctly adjust the low-pressure flushing flow during trimming.
8. Traces of the feed line
When processing the concave mold, dents often appear at the feed line. For some precision molds, the accuracy and surface requirements Very high, the dents on the surface of the workpiece directly affect the surface quality of the product.
(1) It can be improved by advancing and retracting the tool in an arc-in and arc-out manner. When programming, enter the arc entry radius and exit radius, 0.4 to 0.5 is enough.
(2) In the automatically generated program, the code for the offset of introducing and exiting cutting is H000, and the default value is 0, so the cutting in and out are at the same point, forming a secondary discharge , producing dents of a few microns. This phenomenon can be avoided by using the method of inclined advance and inclined retreat to stagger the entry and exit points. You only need to assign a value to H000 in the program, usually 0.03-0.06.
9. The electrode wire breaks frequently when finding the edge
When using 0.15㎜ or 0.1㎜ electrode wire frequently breaks when finding the edge, please check:
The wire tension in the machine tool configuration is incorrect -----The system default setting tension for edge finding is 12. If you change to 0.15mm or 0.1mm electrode wire, you must reduce this tension value, otherwise the wire alignment process will fail. Wire breakage may occur.
Adjust the FW of 0.1㎜ electrode wire to 3; adjust the FW of 0.15㎜ electrode wire to 7.
10. Arc and arc connection error? Alarm
Since some mold drawing files are UG, Master CAM and other 3D software convert them into 2D drawings, and some of the converted 2D drawings have There are errors between corners, arcs and actual dimensions, as well as problems with the connection accuracy of the programming software. When simulating processing after programming, sometimes an alarm will be issued for arc and arc connection errors.
(1) Increase or decrease the arc I or J value in the alarm program line by 0.001.
(2) When using Fikus programming software, you can modify its post-processing configuration file from the original three decimal places to four decimal places. The specific steps are:
1) Find the Fikus installation file Metalcam folder, double-click to find the Fikusvisualcam folder,
2) Find the post folder, double-click to find the cfg folder ,
3) Find the post-processing file edmAGIE-CA Frontier-G61.cfg,
4) Change 3 in item 5 to 4