The Reason and Solution of the Broken Wires of Medium-speed Wire Cut Electrical Discharge Machining(MS-WEDM)

In recent years, with the continuous development of China's manufacturing industry, manufacturers' requirements for machining accuracy have been continuously improved, among which, the need for precisive linear cutting machine is the most urgent. In wire-cutting industry, 

the mainstream “medium-speed wire cut” has been widely used in the fields of mold manufacturing, precisive small parts, special materials, CAM, forming cutting tools, sample processing, and other fields. Because when this kind of machine tool  used for machining some parts, it not only can save the time for making stamping die and also can shorten the cycle time and reduce the cost of production. Therefore, as the apprentice of medium-speed wire, it is necessary for us to understand why the workpiece of the medium-speed wire cut electrical discharge machine will break, and what can we do solve it?

Why there will be broken wires when the workpieces are processed?

In the process of processing the workpiece, it is inevitable to break the wire, the main reasons may be as follows: molybdenum wire’s tension decreased; improper selection of molybdenum wire’s diameter; molybdenum wire oxidized due to poor quality or poor storage; molybdenum wire has been in working area for a long time due to the slow speed of silk-barrel;there are grooves on the surface of the wire rod and conducting block due to long use;poor quality or inappropriate concentrationof working fluid; poordischarge caused bydirty liquid; excessive current caused by improper selection of electrical parameters; a local short circuit results in high temperature due to too tight tracking.

How to solve the problem when there are broken wires?

Check the tensioning force of molybdenum wire; select proper diameter of molybdenum wire; replace molybdenum wire; check whether there are dents on the surface of the wire rod and the conductive block; replace working fluid to professional medium-speed wireworking fluid, which can reduce wire consumption; select appropriate interval and use working fluid suitable for thick part cutting; adjust the feed potentiometer to stabilize the feed;reduce the pulse width, and increase the interval, or reduce the number of power tubes.

With all that said, it's possible that the beginner of medium-speed cutting wire is not very familiar with what it really is.

What is medium-speed wire cut?

The Wire cut Electrical Discharge Machining is also known as the original Chinese Medium-speed Wire Cut Electrical Discharge Machining, which is through continuous moving molybdenum wire (molybdenum electrode wire) as the electrode, to discharge the workpiece in a pulse spark-discharge, so as to remove the metal and cut into shape. The principle is to cut the workpiece repeatedly. At the beginning, faster speed of the silk barrel and stronger high frequency are used to cut. At the end, slower speed of the silk barrel and weaker high frequency current are used to repair the light, thus this can improve the processing surface finish.

Why molybdenum wire can be used as electrode in medium-speed wire cutting?

The reason why molybdenum wire can be used as electrode to cut medium-speed wire is that the precision of molybdenum wire is high, and the wire diameter tolerance can be controlled within 0 to 0.002mm. In addition, molybdenum wire also has super high tensile strength, small elongation, small tight wire, high surface finish, high cutting precision, large roll curvature, consistent wire diameter. It is also very important that molybdenum wire’s breakage rate is low, processing rate is high, stability is good, can achieve stable and long time of continuous processing. In addition, its high cost performance is also prefered by manufacturers.

There are, of course, many other uses of molybdenum wire. For example, molybdenum wire can be used to produce high temperature resistant equipment such as supports, guide rods, and heating rods. It can also be used as wire mesh for heating high temperature furnace materials and support materials, and can also be used in high temperature heat field of molybdenum furnace and tube socket.

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