电极丝区别

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江门五金冲压件加工厂告诉你慢走丝与快走丝的区别

江门五金冲压件加工厂告诉你慢走丝与快走丝的区别-五金百科-[诚瑞丰]很多人都听说过慢走丝，但很少接触快走丝，不了解两者之间存在什么区别，江门五金冲压件加工厂的员工熟悉各种冲压模具工艺，线切割机床是冲压模具加工行业中最常用和最基本的设备，属于模具工程师入行的基础知识，本文将围绕标题进行分析。

1.线速度不同在线切割机床中，根据电极丝工作时的焊丝行进速度来区分快进丝和慢进丝。

快速焊丝的焊接速度一般为300-700m / min；慢速焊丝的焊丝速度一般为3-15m / min。

2.电极丝材料不同钼丝通常用作快丝的电极丝，直径通常为0.1-0.2mm，慢丝电极丝一般采用铜丝或其他金属丝，丝长为0.03-0.035mm。

3.工作润滑液不同对快速移动的金属丝的要求不是太严格，工作流体通常是乳液。

慢速运动的焊丝的工作流体是去离子水或煤油，并且需要配备过滤系统以在生产过程中连续过滤工作流体中的杂质。

4.精确度不同快速移动的焊丝是电极丝的回收利用，因为焊丝继续磨损，影响了加工精度，快丝加工产品的精度为±0.015〜0.02mm；慢速运动丝的电极丝不回收，大大提高了加工精度，机床的加工精度可以达到±0.002mm。

5.加工成本不同高速线切割机床更为普遍，技术含量较低，选用的厂家更多，设备的价格更低。

此外，钼丝可被回收，加工效率也高，加工成本低；慢速剪线机技术含量高，设备昂贵，加工成本也较高。

在冲压模具加工行业中，快丝是最普遍使用的工艺，随着技术的进步，开发人员可基于快速移动的剪线机床开发了一种修边功能，该工具又被称为中动式剪线机床，但其加工精度仍不能与慢丝机相比。

以上就是慢走丝与快走丝之间的5点区别。

各种精密冲件定制加工，生产销售业务，欢迎联系五金冲压件加工厂--诚瑞丰！。

三种特种加工技术的比较

4000瓦
10000瓦
脉冲性能
上升达到同样的功率，脉可调制成脉冲输出模式，冲爬升时间比快轴流激光最高频率5KHZ，响应时器多五倍，峰值功率持续间小于100us，打孔能力、时间远短于快轴流激光器，转角加工质量能量还，保所以打孔能力、转角加工证切割尖角和质量拐角质质量、消除零件下表面挂量。渣能力较差。碳钢、不锈钢，连续切割可连续大量加工一些难加工的金属铜、磷青铜、钼时对射频管影响大。等。 18-20mm 8-10mm 5-6mm(不能连续切割) 厚板稍慢，由于割缝细，速度较慢 15-20mm 8-10mm 6-8mm 薄板速度快，是CO2切割速度的2-3倍，切割质量好，断面完美。
电火花线切割加工、激光加工、水切割加工技术的比较
xxx
主要内容

1.分析三者的工作原理，比较能量利用率；
2.分析三者加工范围，精度，生产效率，性价比；

3.分析各自的互补性，列出各自的优缺点，发展趋势。
加工原理的比较
加工种类区别火花线切割加工时，在电极丝和工件之间进行脉冲放电。电极丝接脉冲电源的负极，工件接脉冲电源的正极。激光加工就是利用其所具有的输出光线的高指向性和高能量，进行微小孔及狭缝等的精密加工、切割、细微焊接等。水切割又叫水射流切割，主要是运用高压水射流，利用刚度差进行切割。加工原理共性
加工范围
加工种类加工范围（加工材料，使用范围）加工模具：各种形状的冲模，只需要一次编成。采用电火花线切割整体加工，使配合精度提高，制造周期缩短，成本降低。加工电火花成型加工用的电极。加工零件：用于试制新产品；电火花线切割单件小批量生产；特殊难加工材料的加工；贵重金属下料。按走丝的快慢可分为：快走丝：走丝速度为6～12 m/s；中走丝；慢走丝电火花线切割的走丝速度为0.2m/s。激光穿孔，如加工航空发动机涡轮叶片等，达到无再铸层、无微裂纹的效果。激光切割薄材，如耐热合金、钛合金、复合材料制成的零件等等。主要是应用于飞机三维蒙皮、框架、舰船船身板架、直升机旋翼、发动机燃烧室等。激光焊接，对高熔点、高反射率、高导热率和物理特性相差很大的金属焊接特别有利。大部分用于汽车工业、宇航和仪表工业等行业。还有激光表面强化；激光快速成形技术等等。可以切割高硬度和不可溶的材料，比如：石材、玻璃、陶瓷、硬质合金、金刚石等。特殊的场地和环境下切割：水下、有可燃气体环境，而电火花以及激光切割却无法实现。

电极丝差别[技巧]

电极丝区别线切割加工中电极丝的选用电火花加工作为一种特种精密加工技术，近年来得到了迅速的发展。

特别是慢走丝线切割加工，已经成为模具制造和金属加工行业必不可少的加工手段。

线切割技术的发展，离不开电极丝技术的同步发展。

因为线切割机的切割效率和切割质量与电极丝的性能紧密相关，而电极丝技术的突破往往会导致线切割机设计的革新。

从1979年镀锌电极丝的发明到今天，市场上不断出现了各种各样比普通黄铜丝性能更好的电极丝，电极丝的正确选用已经成为使线切割机的性能得到最大限度的发挥并为用户创造更多利润的关键。

现在，在欧美和日本等发达国家，以镀锌电极丝为主的高性能电极丝正在逐渐取代放电性能受到很大局限的黄铜丝。

同时，除了早已将镀锌电极丝作为标准配置的线切割机制造商Agie和Charmilles 外，现在Mitsubishi和Sodick公司也在最新的机型上增加了采用镀锌丝的模式和加工参数，使这些设备的切割速度较之采用黄铜丝有30%~50%的显著提升。

但是在国内，前几年由于欧洲进口的镀锌电极丝价格较高，不仅几乎所有的日本、台湾和国产慢走丝机的用户都只用黄铜丝，一些本来使用镀锌电极丝的Agie机和Charmilles机用户，也改用了"便宜"的黄铜丝，造成了相当多的用户以为"电极丝就是黄铜丝"这一行业内的误区。

有不少国内的用户在引进最新高性能的线切割机的同时，忽视了电极丝的重要性，以为它只不过是一种普通的消耗品。

不管什么机型或加工要求，黄铜丝都以其低廉的价格似乎成了唯一的选择。

从2002年起，来自韩国的性价比较好的镀锌电极丝在广东地区为不少用户所采用，取得了明显的效益，至2003年行业内越来越多的用户开始关注镀锌电极丝的应用，"不同的加工，采用不同的电极丝"这一概念开始为精明的线切割用户所接受。

实际上现在的线切割加工有着比过去更多的变化，从加工材料、切割速度、轮廓精度、表面质量到工厂的运行模式等等。

浅谈线切割用黄铜丝和涂层电极丝

镀层电极丝是将加工精度、加工速度及自动穿丝性能等
种种加工特征综合考虑而研制的特殊电极丝。根据镀层材料
所以很多电极丝制造商都采用这种方法来生产镀锌电极丝。但是镀锌后再拉丝，最大的问题是无法控制镀层的均匀性，其所以用这种工艺生产的电极丝放电性能不够稳定，速度只比黄铜丝提高不到１％。有些品质较差的镀锌电极丝其颜色往０
种特别的精密机械加工技术也得到了迅速发展。线切割技
术的发展其重要的一部分依赖于电极丝技术的发展。拥有性
能优良的电极丝才能进行高效地加工，出产高品质、高精度的产品。自２世纪七八十年代镀锌电极丝发明以来，Ｏ市场上先后出现了普通黄铜电极丝、锌电极丝、镀钼丝、丝、钨复合丝
为此我们应多了解一些这两类材料。
１黄铜丝
（）１黄铜丝概述。黄铜丝是线切割领域中第一代专用电极丝。１７９７年，丝开始进入市场，电极丝曾带来了切割黄铜这种速度上的突破，当时对于厚度为５ｍ０ｍ的工件，切割速度从１ｍ／ｉ２ｍ２ｎ提高到２ｍ２ｉ。为什么速度会翻了一倍呢？原ｍ５ｍ／ｎｍ来，黄铜是紫铜与锌的合金，常见的配比是６％的紫铜和最５３％的锌。当时发现黄铜丝中的锌由于熔点较低（２ ℃ ，５４Ｏ而ｌｔ它拉成直径很小的细丝。
延伸率
导电性，ＣＩＳＡ
＜％（）３硬
２％０
口茛面颜色
口釜黄
口
口
口
（）３黄铜丝的主要缺点：割速度难提高：黄铜中 ①切由于锌的比例一定，以放电时的能量转换效率无法进一步提高；所以 ①０２ｒ．ａ５ｍ黄铜丝切割３— ０ｍ厚的钢材为例，０６ｒａ国内很多用户的切割速度都在１０ｍ／ｉ左右。②表面质量不佳：０ｍ２ｎｍ黄铜丝表面的铜粉和放电时由于电极丝表层气化而带出的铜微

工作总结之电火花实习总结

电火花实习总结【篇一：电火花实训报告】电火花实训报告一、零件加工设备的概述：电火花线切割机床由工作台、走丝机构、供液系统、脉冲电源和控制系统等五大部分组成。

电火花线切割加工的基本原理是利用移动的细金属导线（钼丝）做电极对工件进行脉冲火花放电、切割成型的。

2、高速电火花小孔加工机床，型号：dd703f；工作台最大行程：200x300mm；最大穿孔厚度：250mm。

高速电火花小孔机床由六部分组成：电气柜、坐标工作台、主轴头、旋转头、高压工作液系统、光栅数显装置。

高速电火花小孔加工的原理与特点：电极采用铜管，铜管旋转或不旋转，管内通入高压水，铜管与工作之间放电，高压水起到介质、冷却及快速将放电蚀除物排出的作用。

由于在高压水的作用下能够快速将蚀除物从深小孔中排出，所以放电状态良好，加工效率高。

加工孔径为直径0.3到直径3mm。

3、精密单轴数控电火花成形机，型号：hcd300czk；工作台工作面宽度：350mm；工作台工作面长度：630mm；电火花成形加工机床主要包括主机、电源箱、工作液循环过滤系统及附件等。

二、零件加工工艺的制定：电火花线切割电火花线切割加工一般可分以下四个步骤：a、工件图纸的审核与分析a、图纸的分析与方案确定b、凹角和尖角的切割加工的要点c、合理选用表面粗糙度和加工精度d、合理选用工件材料和热处理b、编制加工程序a、编程前的准备（确定间隙补偿量、程序的起点及走向的选择）b、确定加工间隔和过渡圆半径c、计算与编写加工程序d、校对程序c、工件的加工a、加工前的准备b、工件的找正c、电极丝初始位置的确定d、切割加工d、工件的检验a、尺寸精度和配合间隔的检验b、表面粗糙度的检验三、电火花线切割机床、高速电火花小孔加工机床、精密单轴数控电火花成形机在模具行业的运用：1、电火花线切割机床：适用于各种形状的冲模，调整不同的间隙补偿量，只需一次编程就可以切割凸模、凸模固定板、凹模及卸料板等，模具配合间隙、加工精度通常都能达到要求。

18操作线切割机床加工零件(电极丝的引入和校正)

课次授课计划课题：电极丝的引入和校正
课前准备:
找正器刀刃角尺任务操作细化单教学过程设计
任务操作细化单见附
件2
任务操作细化单（程序性任务）
调整U 轴电机调节钮，使找正器与电极丝上下火花均匀一致，即校正X 轴向垂直度，退工作台；
手动低速移动Y 轴拖板，找正器工作面与电极丝产生微弱火花放电，依据火花的不均匀性，判断调整的方向；调整V 轴电机调节钮，使找正器与电极丝上下火花均匀一致，即校正Y 轴向垂直度，退工作台；
精调完成，关高频，关运丝电机。

轻拆找正器，擦干净，收入盒中。

按照5分制给组内成员评价
图5—1
调整U 轴，目
测调整X 轴向垂直度
判断Y 向调整方向
调整V 轴，目测调整Y 轴向
垂直度
关闭火花放电拆下校正器总评。

线切割频繁断丝的原因

线切割频繁断丝的原因介绍线切割是一种常见的金属切割加工方法，它通过在金属工件上生成电弧放电，利用放电产生的高热能将金属切割开。

然而，在实际应用中，我们经常会遇到线切割频繁断丝的问题，即电极丝（切割线）在切割过程中出现断裂的现象。

本文将探讨线切割频繁断丝的原因，并提出解决方法。

原因一：电压不稳定电压是线切割过程中的一个关键参数，它直接影响到电弧放电的稳定性和切割质量。

如果电压不稳定，就会导致电弧放电不均匀，进而影响电极丝的稳定性。

造成电压不稳定的原因有： - 电源问题：电源的质量不过关，输出电压波动较大； - 线路问题：切割机与电源之间的线路老化、接触不良等； - 外界干扰：临近的其他设备、电磁信号等干扰。

原因二：切割速度过快在线切割过程中，切割速度是一个重要的参数。

如果切割速度过快，电极丝在切割过程中受到的拉力就会增大，容易发生断丝现象。

切割速度过快的原因有： - 过高的进给速度：如果进给速度设置过高，切割速度就会过快； - 材料选择不合适：不同的材料对切割速度有不同的要求，如果选择的材料不适合高速切割，就容易发生断丝。

原因三：电极不合适电极是线切割过程中起到导电和切割的作用的部分，它的质量和选择直接影响到线切割的效果和稳定性。

如果选择的电极质量不好或选择不合适，就容易出现断丝问题。

导致断丝的原因有： - 电极质量问题：电极质量差、表面未经处理等； - 电极选择不合适：不同材料需要使用不同类型的电极，如果选择的电极与切割材料不匹配，就会出现问题。

原因四：工作环境不良线切割是一项需要较高的工作环境要求的加工工艺，如果工作环境不良，容易引起线切割频繁断丝。

工作环境不良的原因有： - 温度过高：线切割过程中需要保持适宜的温度范围，太高的环境温度会导致电极丝变形、断裂； - 湿度过大：湿度过大会导致电极丝表面产生氧化，影响导电效果； - 灰尘和杂质：工作环境中存在过多的灰尘、金属屑等杂质，会影响切割的稳定性。

线切割基础知识线切割主要用于加工各种形

线切割基础知识线切割主要用于加工各种形线切割主要用于加工各种形状复杂和精密细小的工件，例如冲裁模的凸模、凹模、凸凹模、固定板、卸料板等，成形刀具、样板、电火花成型加工用的金属电极，各种微细孔槽、窄缝、任意曲线等，具有加工余量小、加工精度高、生产周期短、制造成本低等突出优点，已在生产中获得广泛的应用，目前国内外的电火花线切割机床已占电加工机床总数的60%以上。

根据电极丝的运行速度不同，电火花线切割机床通常分为两类：一类是高速走丝电火花线切割机床(WEDM-HS)，其电极丝作高速往复运动，一般走丝速度为8～10m/s，电极丝可重复使用，加工速度较高，但快速走丝容易造成电极丝抖动和反向时停顿，使加工质量下降，是我国生产和使用的主要机种，也是我国独创的电火花线切割加工模式；另一类是低速走丝电火花线切割机床(WEDM-LS)，其电极丝作低速单向运动，一般走丝速度低于0.2m/s，电极丝放电后不再使用，工作平稳、均匀、抖动小、加工质量较好，但加工速度较低，是国外生产和使用的主要机种。

根据对电极丝运动轨迹的控制形式不同，电火花线切割机床又可分为三种：一种是靠模仿形控制，其在进行线切割加工前，预先制造出与工件形状相同的靠模，加工时把工件毛坯和靠模同时装夹在机床工作台上，在切割过程中电极丝紧紧地贴着靠模边缘作轨迹移动，从而切割出与靠模形状和精度相同的工件来；另一种是光电跟踪控制，其在进行线切割加工前，先根据零件图样按一定放大比例描绘出一张光电跟踪图，加工时将图样置于机床的光电跟踪台上，跟踪台上的光电头始终追随墨线图形的轨迹运动，再借助于电气、机械的联动，控制机床工作台连同工件相对电极丝做相似形的运动，从而切割出与图样形状相同的工件来；再一种是数字程序控制，采用先进的数字化自动控制技术，驱动机床按照加工前根据工件几何形状参数预先编制好的数控加工程序自动完成加工，不需要制作靠模样板也无需绘制放大图，比前面两种控制形式具有更高的加工精度和广阔的应用范围，目前国内外95%以上的电火花线切割机床都已采用数控化。

浅谈快丝与慢丝

浅谈慢丝与快丝的区别区别一：走丝的速度。

快走丝走丝速度大于等于2.5m/s，常用值6至10m/s，而慢走丝线切割走丝速度是小于等于2.5m/s。

常用值0.25至0.001m/s。

区别二：电极丝工作状态。

快走丝线切割机床是往复供丝，反复使用。

慢走丝线切割机床是单向动行，一次性使用。

区别三：电极丝材料。

快走丝线切割机床的电极丝材料是采用钼丝、钨钼合金，而慢走丝线切割是采用黄铜、铜、以铜为主体的合金或镀复材料的电极丝。

区别四：电极丝直径。

快走丝线切割机床电极丝的直径0.03至0.25mm,常用值直径为0.12至0.2mm，而慢走丝线切割电极丝的直径0.003至0.3mm,常用值直径为0.2mm区别五：穿丝方式。

快走丝线切割的穿丝方式只能是手工，而慢走丝线切割穿丝方式可以是手动的也可是自动。

区别六：工作电极丝长度。

快走丝线切割工作电极丝长度是数百米，而慢走丝线切割的工作电极丝长度为数千米。

区别七：电极丝振动。

快走丝线切割的电极丝振动较大，而慢走丝线切割的电极丝振动摇较小。

区别八：电极丝张力。

快走丝线切割的电极丝张力上丝后就固定不变，而慢走丝线切割的电极丝张力上丝后，可调，通常2.0至25区别九：运丝系统结构。

快走丝线切割机床运丝系统结构较简单，而慢走丝线切割机床动丝系统结构较复杂。

区别十：脉冲电源。

快走丝线切割机床开路电压80~100V，工作电流通1~5A，而慢走丝线切割机床开路电压300V，工作电流通1~32A区别十一：工作液。

快走丝线切割机床工作液是乳代液或水基工作液，而慢走丝线切割机床是去离子水，个别场合用煤油。

区别十二：工作液电阻率。

快走丝线切割机床工作液电阻率是0.5~50，而慢走丝线切割机床工作液电阻率10~100.区别十二：导丝机构型式。

快走丝线切割机床导丝机构型式是采用导轮，寿命较短，而慢走丝线切割机床工作液导丝机构型式是采用导向器，寿命较度。

区别十三：价格不一样。

快走丝线切割价格便宜，慢走丝线切割价格贵。

电极丝材料

电极丝是一种在电化学加工中作为阳极或阴极的材料。

不同的加工方法和材料对电极丝的要求也不同，因此电极丝材料的选用非常关键。

以下是一些常见的电极丝材料：
1. 紫铜：具有良好的导电性和耐腐蚀性，但强度较低。

常用于线切割加工等领域。

2. 石墨：具有良好的导电性和耐高温性，但易脆断裂。

常用于电火花加工等领域。

3. 铜钨合金：具有高强度、高导电性和耐高温性，但价格较高。

常用于高精度和高效率的电火花加工等领域。

4. 银钨合金：具有优良的导电性和耐腐蚀性，但价格较高。

常用于需要高精度和高效率的电火花加工等领域。

5. 钢：强度高，价格低廉，但导电性和耐腐蚀性较差。

常用于对精度要求不高的电火花加工等领域。

6. 黄铜：具有较高的强度和耐磨性，但导电性和耐腐蚀性较差。

常用于对精度要求不高的切割和铣削等领域。

除此之外，还有镀锌丝、钼丝、钨丝、钢丝等材料可供选择。

不同的电极丝材料具有不同的特点，应根据具体加工需求和条件进行选择。

如何正确地选择电极丝

如何正确地选择电极丝作者：oa161商务办公网从开端运用的无氧铜丝切开到如今的复合线进行切开，慢走丝切开的展开履历了从低功率、低质量到高功率、高质量、自动化和专业化出产的一个漫长的进程。

要知道，电极丝的正确选用是前进加工质量、前进机床功率、减少人工本钱的关键所在。

一种新技能的引进，要通过模仿、吸收、消化、立异这一进程，理论研讨发现，电极线中锌含量越高,切开效果会越好，可是从有色金属加工学上来讲，当锌的比例逾越40%往后，电极丝的α单相结晶组织成为了有α和β组成的双相结晶组织，这时材料变得太脆而不适合把它加工成直径很小的细丝。

因此通常黄铜电极丝在广泛寻求高功率切开的今天遭到了加工技能方面的束缚，这样就派生出了有其他分外功用的电极丝。

1.电极丝材料特性要研讨开发出产一种新的电极丝，首要要认识到成为电极丝材料所具有的底子特性，根据如今国内外技能的研讨，总结得出，制造电极丝的材料有必要具有以下特性：（1）机械特性。

在电火花放电加工进程中，电极丝是要承受一定的拉力和因放电致使的冲击力的。

如果这种材料的强度太低或许开裂耐性太低，在切开时，电极丝会颤抖，致使切开工件表面的不光滑，甚至会致使一道一道的切开线痕。

另外强度对保证电极丝恢复直度的功用也有效果，一样电极丝材料具有一定的延伸性对切开有斜度的工件也比较有利。

（2）气化特性。

在加工进程中，放电所发生的热量是不断增加的，而这种热量如果不可以通过其他介质及时地排放出去，熔点再高的电极丝材料也会被熔化掉（电极丝应用领域所讲的烧断丝），因此组成电极丝的材料有必要有将这些热量带出去的功用。

（3）物理特性。

电极丝的物理特性是前进切开功率的关键所在，这些特性是通过电极丝材料的基础成分的配比及芯材的组成金属性质所抉择的。

因为电极丝在切开时的颤抖会发生霎时间的短路效应，这时切开进程会减慢，如果这时电极丝的表面金属不会因为放电烧蚀掉一部分，电极丝和切开金属之间就不会发生空地，那么所发生的切开废屑就不会因为冲水的效果而排出去，这时电极丝就会烧断，一样也不能进行切开。

电极丝绕丝步骤和注意事项

电极丝绕丝步骤和注意事项电极丝绕丝是一种常见的金属加工工艺，用于将金属丝绕绕在电极上，以供电和导电作用。

下面我将详细介绍电极丝绕丝的步骤和注意事项。

一、电极丝绕丝步骤:1.准备工作：首先确定要绕丝的电极类型和规格，选择合适的金属丝进行绕丝。

然后准备好绕丝机器和工具，包括绕丝机、丝轴、电极轮、切断器、焊锡等。

2.调整绕丝机：将绕丝机的参数调整到适合绕丝的状态，包括线速度、张力、电极轮的转速等。

根据电极的直径和长度来调整绕丝机的参数。

3.固定电极：将要绕丝的电极放置在绕丝机上，用合适的夹具将电极固定住，确保电极在绕丝过程中不会移动或晃动。

4.将金属丝固定在丝轴上：将金属丝固定在丝轴上，确保丝轴能够顺畅地旋转。

可以使用胶带或夹具将金属丝固定。

5.开始绕丝：将丝轴放置在绕丝机的正上方，将丝轴上的金属丝通过电极轮进行引导，开始绕丝。

注意控制绕丝的速度和张力，保持电极表面均匀且不松动。

6.检查绕丝质量：在绕丝过程中，及时检查绕丝质量，主要包括绕丝的紧密度、表面平整度和焊点的牢固度等。

如有问题及时进行调整和修复。

7.绕丝完成：当绕丝到达设计要求的长度时，停止绕丝机的运行。

将绕好的电极取下，进行剪断和修整，使其符合设计要求。

二、电极丝绕丝注意事项：1.安全操作：在进行电极丝绕丝时，要注意安全操作，佩戴好防护设备，避免发生意外事故。

2.保持整洁：保持工作环境整洁，妥善摆放机器和工具，避免杂物和堆积物对操作造成干扰。

3.选择合适的金属丝：根据不同的电极类型和要求，选择合适的金属丝进行绕丝，确保电极的导电性能和使用寿命。

4.调整绕丝机参数：根据电极的直径和长度，合理调整绕丝机的参数，包括线速度、张力和电极轮的转速等，保证绕丝质量。

5.固定电极位置：在绕丝前，要将电极固定好，避免绕丝过程中电极的晃动或移位，影响绕丝质量。

6.控制绕丝速度和张力：在绕丝过程中，要控制绕丝的速度和张力，保持电极表面的均匀和紧密，避免绕丝过紧或过松。

电火花线切割加工时电极丝和工件之间的脉冲放电

线切割机床的分类
(1)根据控制方式的不同，电火花线切割机床分为：电气靠模线切割机床；光电跟踪线切割机床；数字控制线切割机床。 (2)根据电极丝走丝方式的不同，数控线切割机床分为：快走丝线切割机床；慢走丝线切割机床。
1)快走丝线切割机床 ①线电极运行速度较快(300—700m／min)。 ②可双向往复运行，即丝电极可重复使用，直到丝电极损耗到一定程度或断丝为止。 ③常用线电极为：钼丝(Φ0.1～Φ0.2mm)。 ④工作液通常为：乳化液或皂化液。 ⑤由于电极丝的损耗和电极丝运动过程中换向的影响，其加工精度要比慢走丝差，表面粗糙度要高； ⑥尺寸精度：0.015～0.02mm； ⑦表面粗糙度Rɑ：1．25～2.5μm。 ⑧一般尺寸精度最高可达到：0．01mm，表面粗糙度Rɑ为：0.63～1.25μm。
2)慢走丝线切割机床 ①线电极运行速度较低(0.5～15m/min)。 ②线电极只能单向运动，不能重复使用，这样可避免电极损耗对加工精度的影响。 ③丝电极有：紫铜、黄铜、钨、钼和各种合金，直径一般为0.1～0.35mm。 ④工作液：去离子水、煤油。 ⑤尺寸精度：±0.001mm ⑥表面粗糙度：Ry0.3μm。
数控电火花线切割加工
前言
传统的切削加工方法主要依靠机械能来切除金属材料或非金属材料。随着工业生产和科学技术的发展，产生了多种利用其他能量形式进行加工的特种加工方法，主要是指直接利用电能、化学能、声能和光能等来进行加工的方法。在此，机械能以外的能量形式的应用是特种加工区别于传统加工的一个显著标志。
电火花线切割机床组成
1．机床主体：床身、丝架、走丝机构、X—Y数控工作台 2．工作液系统 3. 高频电源：产生高频矩形脉冲，脉冲信号的幅值、脉冲宽度可以根据不同工作状况调节。 4. 数控和伺服系统

电极丝简介(DOC)

电火花加工作为一种特种精密加工技术，近年来得到了迅速的发展。

特别是慢走丝线切割加工，已经成为模具制造和金属加工行业必不可少的加工手段。

线切割技术的发展，离不开电极丝技术的同步发展。

因为线切割机的切割效率和切割质量与电极丝的性能紧密相关，而电极丝技术的突破往往会导致线切割机设计的革新。

现在，在欧美和日本等发达国家，以镀锌电极丝为主的高性能电极丝正在逐渐取代放电性能受到很大局限的黄铜丝。

同时，除了早已将镀锌电极丝作为标准配置的线切割机制造商Agie和Charmilles外，现在Mitsubishi和Sodick公司也在最新的机型上增加了采用镀锌丝的模式和加工参数，使这些设备的切割速度较之采用黄铜丝有30%~50%的显著提升。

有不少国内的用户在引进最新高性能的线切割机的同时，忽视了电极丝的重要性，以为它只不过是一种普通的消耗品。

不管什么机型或加工要求，黄铜丝都以其低廉的价格似乎成了唯一的选择。

实际上现在的线切割加工有着比过去更多的变化，从加工材料、切割速度、轮廓精度、表面质量到工厂的运行模式等等。

第4节电极的种类分析

第4节电极的种类分析
电极是指用于连接电路的金属器件，它们能够将电路与外部的电源或
其他电气元件连接起来，让电路可以正常的工作起来。

此外，它们还能够
将电路中的能量以电流或电压的方式释放出来或者接收其他外部的能量。

通常情况下，电极由金属丝或螺杆组成，它们可以用于连接电路，也可以
用于连接电路和外部电源。

根据电极的不同用途，可以分为很多种，其中常见的有碳电极、钨电极、钛电极和金属电极等。

碳电极是最常见的一种电极，它由碳元素组成，由于碳元素具有很好
的电导性能，故碳电极具有良好的电导性能，可用于电路中的连接和释放
电能。

不仅如此，碳电极还具有易受热和耐热性，通常它们被用于电路中
的熔断器、自动控制器等。

钨电极是一种特殊的电极，它们由钨元素组成，它们具有高密度、高
热导率和高电导率，所以可用于高温的电路中，例如电焊机和低压电路中，可以有效的保护电路不受热的影响，从而提高电路的可靠性。

钛电极是一种具有很高强度的电极，它们由钛元素组成，钛电极具有
高的耐腐蚀性，高温极限和低温极限，因此可以用于大电流的电路中，例
如在电路的变压器中。

电火花线切割实习报告

竭诚为您提供优质文档/双击可除电火花线切割实习报告篇一：线切割、电火花加工实习报告线切割、电火花加工实习报告时间:20XX-09-2318:36来源:互联网作者:佚名第二类是低速走丝电火花线切割机床（wedm-ls），其电极丝作低速单向活动，平凡走丝速率低于0.2m/s，电极丝放电后不再使用，使命平稳、匀称、抖动小、加工品质较好，但加工速率较低，是外洋生产和使用的重要机种。

再一种是数字程序放肆，采纳先进的数字化主动放肆技术，驱动机床按照加工前按照工件几何形状参数预先体例好的数控加工程序主动实现加工，不需要打造面目板也无需绘制放大图，比后面两种放肆方法存在更高的加工精度和开阔宽大旷达的使用范畴，目前国内外95％以上的电火花线切割机床都已采纳数控化。

进行电火花加工时，东西电极和工件分别接脉冲电源的两极，并浸入使命液中，或将使命液充入放电间隙。

颠末间隙主动放肆琐屑放肆东西电极向工件进给，当两电极间的间隙达到确定距离时，两电极上施加的脉冲电压将使命液击穿，发生火花放电。

在放电的微细通道中刹时汇合大量的热能，温度可高达一万摄氏度以上，压力也有急巨变化，从而使这一点使命概况部门微量的金属材料即时凝聚、气化，并爆炸式地飞溅就使命液中，迅速冷凝，构成固体的金属微粒，被使命液带走。

这时在工件概况上便留下一个微小的凹坑痕迹，放电悠久停息，两电极间使命液回复复兴绝缘形态。

紧接着，下一个脉冲电压又在两电极绝对濒临的另一点处击穿，发生火花放电，反复上述过程。

这样，虽然每个脉冲放电蚀除的金属量极少，但因每秒有擢举事数次脉冲放电感召，就能蚀除较多的金属，存在确定的生产率。

都说眼睛是不会欺骗本人的，但是有时候眼睛是会哄人的看似复杂的东西并不定然可以做好，只有亲自理论才知其奥妙，才会做出抱负的产品，理论是学习的差错！如果再有机遇我还会参加这样的实习，还会去用理论来圆满本人的知识面和本人的各项才能，以求在走出校园的时候有顺应社会的更高的才能。

佳能8500更换转印电极丝

如何更换电极丝此文主要靠自己多动手啊，因为太多的客户及维修员为这个问题所困扰，但他们都说自己整好了电极座及电极丝，所以才详细写一下，希望有所帮助。

电极座容易漏电，这个是佳能挥之不去的阴影，从模拟到数码，只有改进，没有根除，当然其它机器也有这各种各样的漏电现像，本文主要讲佳能，在梅雨季节情况更为严重，转印带的机器稍微强一点，但也有漏电现像。

什么情况下需要清理电极座及更换电极丝？在转印、分离不良、黑度不足、文件上面有一道一道的白道的时候，在清洁不能解决问题的时候就需要更换电极丝了。

电极丝一般换一次可使用10万张左右，以后每清洁一次可使用3-5万张左右，清洁可用干布点着洗洁精或者车腊清洁电极丝及删极（删极就是充电座外面那个银色好多根的那个丝），这个丝一般要把两面的那个铁板都拆下来用布点着洗洁精夹着清洁，这样可以里外都清洁到删极丝。

电极丝及删极丝粘上碳粉同纸屑后会造成文件太淡，转印及分离电极也是同样的道理及时候进行更换及清洁。

换电极丝的时候请先看清楚原装的是什么样子的及方法，最好是先仔细看清楚手册上面的那个章节，换的时候要有一个很好的剪刀及镊子，先用原子笔芯做好一头，这一头要用镊子夹住弹簧先量好距离，结头先看看原装的，要做到电极丝有张紧力还有高度一致的放到那个渠里，头子不要留得太长以免漏电，最利害的就是齐着那个接头剪了。

上好后试试张力及看看两个头子是不是太差了，不行就重新换，行的话就试机，如果一边深一边浅，看看是不是电极高度高上到位不在一个平面，如果眼观在一个平面就调整反面的那个塑料镙丝，顺时针是浅，逆时针就是深。

有些人以为很简单其实，是不是每一步都做得对呢？下面是以图来讲解，如果实际当中浪费太多电极丝了，可以先用缝衣服的线炼好手后才上电极丝。

本文以GP605/IR8500/7200转印座为例子。

图一电极座可能有些说法会与维修手册叫法有点不一样，我有时所讲的叫法会按维修员的习惯叫法来讲，希望大家有时间看看书对照来理解一下。

康奈尔电极丝成分

康奈尔电极丝成分是一种高纯度钨丝，其主要特点是耐高温、耐腐蚀、抗氧化和良好的导热性能。

这种电极丝通常用于制作电子管、灯泡、电视显像管等电子器件。

康奈尔电极丝是由钨制成的，钨是一种具有高熔点、高硬度、抗腐蚀和抗氧化性能的金属。

康奈尔电极丝的制备过程包括钨粉的熔炼、成型、烧结和拉拔等步骤。

在制备过程中，可以通过调整钨粉的纯度、添加其他合金元素和控制烧结条件等方式来控制康奈尔电极丝的性能。

康奈尔电极丝的应用非常广泛，它不仅用于电子器件，还用于航空航天、机械制造、石油化工等领域。

例如，在航空航天领域，康奈尔电极丝可以用于制造火箭发动机喷嘴、燃气涡轮机叶片等高温、高压、高载荷的部件；在机械制造领域，康奈尔电极丝可以用于制造硬度高、耐磨性好的刀具、模具等；在石油化工领域，康奈尔电极丝可以用于制造耐腐蚀、抗氧化性能好的催化剂和加热器等。

电极丝区别(Difference of electrode wire)

电极丝区别（Difference of electrode wire）Selection of electrode wire in WEDMAs a special precision machining technology, EDM has developed rapidly in recent years. Especially in WEDM, has become an indispensable tool in mould manufacturing and metal processing industry. The development of wire cutting technology can not be separated from the simultaneous development of wire electrode technology. Because the cutting efficiency and cutting quality of wire cutting machine are closely related to the performance of electrode wire, the breakthrough of wire electrode technology often leads to the innovation of wire cutting machine design. From 1979 to today's invention galvanized wire electrode, the market constantly appears all kinds of ordinary brass wire electrode is better than the performance of the correct selection of wire electrode has become the key to the performance of wire cutting machine to maximize and create more profits for the user.Now, in developed countries such as Europe and America and Japan, high-performance wire electrodes based on galvanized wire electrodes are gradually replacing the brass wires whose discharge performance is greatly limited. At the same time, in addition to already galvanized wire electrode as the standard configuration of the wire cutting machine manufacturer Agie and Charmilles, now Mitsubishi and Sodick is also the latest models increase model and machining parameters using galvanized wire, significantly improve the cutting speed of these devices compared with brass 30%~50%.But in China, a few years ago because of imported European zinccoated wire electrode is the higher the price, not only Japan, Taiwan and domestic wire walking machine almost all of the users are only brass, galvanized wire electrode should use Agie and Charmilles users, but also use the "cheap" brass has caused considerable the user thought the misunderstanding of "yellow wire electrode wire is" in the industry. There are many domestic users in the introduction of the latest high performance wire cutting machine at the same time, ignoring the importance of electrode wire, think it is only a common consumables. Regardless of the type or processing requirements, the brass wire seems to be the only option at a low price. From 2002 onwards, from South Korea's cost-effective galvanized wire electrode used for many users in the Guangdong area, obtain obvious benefits to more and more users in 2003 industry began to focus on the application of galvanized wire electrode, different processing, using different electrode wire "this concept began to smart line cutting user acceptance. In fact, wire cutting has more changes than ever before, from machining materials, cutting speed, contouring accuracy, surface quality to the operation of the factory, and so on. For these interacting variables, only the selection of the appropriate electrode wire can enable the plant to optimize the processing efficiency, processing costs and processing quality as a whole.First, the performance of electrode wireHigh performance wire must be an organic combination of various useful properties. Then what are the useful characteristics of the wire?1. Electrical characteristicsModern wire cutting power supply puts strict requirements on electrode wire. It must be able to withstand more than 700 amperes peak or average cutting current greater than 45 amperes, and energy transmission must be very effective, can provide high surface finish (above 0.2Ra) high frequency current pulse required. It depends on the resistance or conductivity of the wire. Red copper is one of the highest conductivity materials. It is used as a benchmark for other materials. The conductivity of red copper is marked 100%IACS (International Annealed Copper Standard), while the conductivity of brass is 20%.2. Mechanical characteristicsTensile strength:Tensile strength is a measure of the ability of materials to withstand fracture when subjected to radial loads. It is scaled by the weight of the unit cross-sectional area, such as the British PSI (pound / square inch) or metric N/mm2 (Newton / mm2). Copper is the material with the lowest tensile strength (245N/mm2), while molybdenum is the highest (1930N/mm2). The tensile strength of the wire depends on the choice of materials and various heat treatment and tensile treatment processes. The wire is sometimes divided into "soft silk" and "hard silk", for different equipment and applications,Each has its merits.Memory effect:This is directly related to the "soft" or "hard" of the wire. The soft silk does not have the memory ability to return to the straight line when it is drawn out of the offline shaft, so it can not be used for automatic threading, but this has no effect on cutting because the electrode wire is added with tension at the time of processing. Soft silk is suitable for the upper and lower guide wire nozzle can not tilt equipment, more than 7 degrees of high slope cutting. The hard wire is the best choice for the automatic threading machine. At the same time, because of its high tensile strength, it is resistant to the current of the cutting and the ability to wash the silk caused by the ability to shake.Elongation:Elongation is the percentage of wire length change due to tension and heat in the cutting process. The elongation of soft silk can be as large as 20%, while hard silk is less than 2%. When the soft silk is processed in the slope, the electrode wire with high elongation can ensure the geometric accuracy of the inclined plane, and the vibration of the soft electrode wire is smaller when the guide wire is slid. However, when the wire is cut into the cutting area, the soft wire is more flexible than the hard wire, so it has to be considered in a different way.3, geometric characteristicsIn the early days of the online cutting technology (from the mid 1969 to the mid 70s), almost no research was done on the electrode wire, using a ready-made copper wire on the motor andcable. Today, the high efficiency and high precision wire cutting machine requires the electrode wire to have very little geometric characteristics. The final process of making the electrode wire is to use a number of gem drawing dies to produce a finished product with a smooth, excellent roundness and a +/-0.001mm tolerance of wire diameter. On the other hand, some wire electrodes are specially designed to have relatively rough surfaces that can improve cutting speed.4. Thermophysical propertiesThe thermal physical characteristics of the electrode wire is the key to improve the cutting efficiency. These characteristics are determined by the ratio of the alloy composition or the choice of the base core material.Melting point:The melting point of electrode wire is an important index. Because of the mechanical movement of the electrode wire through the guide wire, as well as the factors such as flushing force and discharge, the electrode wire is vibrating when cutting. This will result in numerous minimal short circuits that slow down the cutting process. When the electrode wire is working, if it can be lost on the outer diameter, the gap in the face of the cut can prevent or reduce the short-circuit effect. At the same time, the gap in the back of the incision helps to improve the flushing effect, and can better remove the waste. The loss of the outer diameter of the electrode wire will not affect the machining accuracy because the new electrode wire is continuously feeding. This is one of the two propertiesof a material to be considered when a scientist studies the rinsing of an electrode wire.Gasification pressure:EDM produces a large amount of heat, some of which is absorbed by the wire, which reduces the cutting efficiency. If too much heat is lost on the wire, the wire will fuse because of overheating. Therefore, the electrode wire surface can be rapidly gasified, and the heat energy is released to the workpiece while the electrode wire is cooled. When the material is heated to the point of melting, it will be gasified to produce gasification pressure. Materials with lower melting point are more likely to be gasified. Another characteristic of the wire should be low melting point and high gasification pressure which can help to blow the waste away from the kerf. This is another characteristic that the wire should be well rinsed. When the wire and the workpiece are gasified at the cutting surface instead of melting, the gas is produced instead of the molten metal particles. This, in turn, improves the washout process because the particles to be washed away are less.Two 、 kinds and application of electrode wireAt present, the market available electrode wire can be divided into the following categories:1, Huang TongsiYellow copper wire is the first generation of professional wire electrode in wire cutting field. In 1977, yellow copper wirebegan to enter the market. This wire has brought a breakthrough in cutting speed, when the thickness of the workpiece 50mm, cutting speed increased from 12mm2/ minutes to 25 mm2/ minutes. What made the speed double? Brass is the alloy of copper and zinc, the most common ratio is 65% of copper and 35% of zinc.It was found that the zinc in the brass wire can improve the flushing property due to the lower melting point (420 DEG C and 1080 Cu). During the cutting process, the zinc is vaporized due to high temperature, which reduces the temperature of the electrode wire and transfers heat to the machined surface of the workpiece. In theory, the higher the ratio of zinc, but in the process of making brass wire, when the ratio of zinc exceeds 40%, the alpha crystalline structure of the wire becomes alpha and beta dual phase crystalline structure. At this point the material becomes too brittle to fit into small filaments of small diameter.The yellow copper wire can have different tensile strength to meet different equipment and application occasions. This is achieved by a series of wire drawing (quenching) and heat treatment (annealing) processes. The tensile strength of plain brass wire is between 490-900N/mm2.The main drawback of brass wire:(1) the processing speed can not be improved because of zinc in brass in a certain proportion, so the energy conversion efficiency of discharge cannot be further improved; the 0.25mm copper wire cutting 30-60mm thick steel as an example, the main cutting speed of many domestic users in 120mm2/ minutes.(2) the surface quality is poor: the copper powder on the surface of the brass wire and the copper particles produced by the gasification of the electrode wire surface are deposited on the machined surface of the workpiece to form a surface copper. At the same time, due to poor flushing, the surface of the workpiece has a thicker metamorphic layer, which will affect the surface hardness and roughness of the workpiece;(3) the machining accuracy is not high: especially in the processing of thicker workpiece, because of poor flushing, it will produce greater straightness error (upper and lower end size error and drum shape difference).In addition, due to the price competition, the current domestic price of copper wire exists all kinds of quality problems, such as copper billet material used and bad drawing equipment and process causes more brass surface of copper, the geometric error is too large and so on, all these will lead to the discharge stability decreases, seriously affect the processing speed and quality. At the same time, it will pollute the parts of the equipment and increase the consumption of the equipment.Application of brass wire:(1) insufficient processing capacity, not 24 hours boot users. Because processing efficiency is not a major concern for these users;(2) users who do not require high machining accuracy, especially surface quality;(3) processing of small size, thin thickness based users. Because the timing of workpiece clamping adjustment accounts for a higher proportion of the total processing time, cutting time is less, the impact on the processing efficiency is not obvious.(4) the material hardness of the workpiece is not high or the thickness is not more than 80-100mm.Although with the better performance of various coated wire electrode and the popularity of brass market share showed a downward trend, but because of its low cost, and can meet the processing needs of ordinary, and therefore will continue to be widely used. At the same time, a new type of yellow copper wire with different performance and lower price than coating electrode has appeared on the market:(1) super clean yellow copper wire: Aiming at the disadvantage of excessive copper on the surface of the ordinary brass wire, it is made by adding special cleaning technology in the rear process;(2) super hard yellow copper wire: by adding other trace elements in brass, the tensile strength of yellow copper wire is as high as 1200 N/mm2. This kind of wire can improve machining accuracy and speed when machining super thick or super hard workpiece;(3) high speed yellow copper wire: increase the proportion of zinc in the brass to 40% of the limit. It can improve the qualityof the washing and improve the cutting speed. However, the cutting speed is slower than the galvanized wire.2 、 coating electrode wireDue to the low melting point of zinc has a significant role to improve the discharge performance of wire electrode, and brass zinc ratio is limited, so people thought with a layer of zinc in brass outside, which produced a galvanized wire electrode. In 1979, several Swiss engineers invented this method to make the development of electrode wire a big step forward,And lead to the emergence of more new type of coated electrode wire.The main advantages of coated electrode wire:(1) cutting speed is high, it is difficult to break the thread. Good quality galvanized wire cutting speed of high-quality brass wire fast 30-50%, at present, many users in Guangdong 0.25mm galvanized wire electrode, cutting speed averaged 150-180mm2/ minutes.(2) the surface quality of the machined workpiece is good, the copper free deposit is improved, and the deterioration layer is improved; therefore, the hardness of the workpiece surface is higher, and the service life of the die is prolonged.(3) the machining accuracy is improved, especially the shape error at the sharp corners and the straightness error of the thick workpiece are better than those of the yellow copper wire.(4) the loss of the guide wire, nozzle and other parts is reduced. The hardness of zinc is lower than that of brass. At the same time, galvanized wire doesn't have a lot of copper powder like brass wire, so it is not easy to block guide wire and pollute related parts.There are three methods for the production of coated electrode wire, impregnation, electroplating and diffusion annealing. The core materials of electrode wire include brass, copper and steel. Coating materials are zinc, copper, copper, zinc alloy and silver. At present, the market is more mature of this type of electrode wire, according to the application of distinction, mainly in the following:Ordinary galvanized wire:Because the impregnation process is relatively simple, many electrode manufacturers use this method to produce galvanized wire. However, after galvanizing and drawing, the biggest problem is that the uniformity of the coating can not be controlled. Therefore, the discharge performance of the electrode wire produced by this process is not stable enough, and the speed is only increased by 10% less than that of the brass wire. Some of the poor quality galvanized wire, its color is often not uniform gray silver, you can see some light yellow, which is the so-called "exposed copper" phenomenon. Although this kind of electrode wire is cheaper, it is only a little more expensive than copper wire, but not many people use it.Zinc coated electrode wire for high precision machining:The electrode wires are mostly electroplated, so the thickness of the galvanized layer can be better controlled, the discharge performance is stable, the wire is not easy to break, and the utility model is suitable for the precise processing of the four cutting. Cutting speed can generally be about 30% faster than brass wire. See the section of the electrode wire. The most common brands are Berkenhoff, CUT, A, MEGACUT, A, STAMMCUT, Stamm, ZC900 and ZC950 from Heinrich, Germany, COBRA, and so on.The ZINCO series zinc plated electrode wire of Korea OPEC Co., Ltd., although it is also used in dipping process, has different technological methods, and has applied to the invention patents of the United States, Japan, Europe and china. The process is characterized by that the brass core is drawn to the end of the final diameter to be plated and then brushed. The coating is composed of multilayer copper and zinc alloy, and the ratio of zinc varies from inside to outside, and the zinc in the outer layer is the most, and the surface is helpful to improve the micro porous structure of the washing property. The wire has been adopted by wire cutting machine manufacturers Sodick and Agie-Charmilles. It is also the best galvanized wire in China at present.Beginning this year, South Korea has several home appliance manufacturers are also trying to use the electroplating method of production of galvanized wire, and if you can form a batch into the market, I believe it will bring more benefits to domestic users.Coated electrode wire for high speed machiningThe electrode is produced by a diffusion annealing process. It is a composite electrode with a thicker coating containing 50% zinc and 50% red copper. The coating is subjected to a series of heat treatment processes in which the color is changed from bright silver to brown. The core of the electrode wire is an alpha structure, and the coating is a beta structure, which is finally subjected to a stretching process to press the coating into the core by cold pressing. The surface of the diffused wire electrode is porous and helps to improve the flushing property. The cutting speed of the electrode wire is the fastest. Common brands are COBRA, CUT, D, BRONCO, CUT, X, MEGACUT, D, SWX, STAMMCUT, Xi and so on.South Korea OPEC company for Charmilles HUNT-X WEDM wire electrode machine is developed, though not by diffusion annealing, but the cutting performance and the electrode wire is very similar, also belong to the high speed wire electrode, can be used for processing high demands on speed.Coated electrode wire for high difficulty machiningThe steel cored wire is a kind of composite yarn. It consists of a steel core with an inner copper coating and a brass coating outside. The tensile strength of the steel core at room temperature is similar to that of the brass wire, but the tensile strength of the brass wire decreases rapidly as the temperature increases, while the tensile strength of the steel is higher than that of the brass wire. However, because of the poor electrical conductivity of the harbor, a layer of copperis applied outside the steel core to increase the conductivity. The brass layer outside can improve the performance of the washing.For a higher degree of WEDM, although the use of coarse diameter (0.30mm) of the electrode wire, or galvanized wire electrode can make the situation has improved, but processing to achieve higher requirements, the best choice is the steel core wire electrode.1, high thickness processing: in general, when the processing of workpiece thickness (usually more than 100mm), processing speed decreased significantly, and processing surface straightness error will be very big. At this point, the use of steel cored wire processing, can significantly improve speed and accuracy.2, the processing of poor water conditions: such as high slope processing, workpiece thickness of irregular, larger range of processing and multiple workpiece superimposed processing, and so on. Poor water flushing is likely to cause wire breakage and the machining speed decreases. At the same time, the two discharge will also increase, affecting the surface quality.3, workpiece materials difficult to process: such as graphite, copper, aluminum alloy and other difficult to cut materials.Common brands are: Japan FUJIKURA company's COMPEED steel core electrode wire.Electrode wire for ultra precision machiningThe diameter of yellow copper wire or coating wire is usually between 0.30mm and 0.07mm. For some electronic, optical and watch industries, fine or ultra precision machining requires wire diameters ranging from 0.10mm to 0.03mm. In the past, this kind of wire was made of tungsten wire or molybdenum wire, and the price was very expensive. Now widely used high tensile steel wire (100 carbon piano line) outside with brass plating to make, commonly known as "piano line."". The tensile strength of the electrode wire is 2 times as high as that of the conventional electrode wire, and the tensile strength is as high as 2000 N/mm2 or more. The most common brands are German MICRO CUT, Japanese SPWire.Three, how to consider the influence of different electrode wires on processing cost?Want to work its effect, first benefit its device". The new equipment, new tools and new materials in the manufacturing industry bring about better processing results and higher processing efficiency, and it also means better economic results. The first to benefit from the industry are those who are familiar with technology development trends and adopt advanced technology first. This is exactly the same for wire cutting. With the continuous development of wire cutting technology and the pursuit of efficiency and quality, the new high-performance wire will inevitably replace brass wire and become the leading role in the market. The adoption of high efficiency wire electrodes will have a profound impact on the financial statements or competitive ability of the users of the wire cutting machine. We study the relationship betweenprocessing status and processing cost in the following aspects:1, the processing capacity of the existing equipment in the factory, whether it meets the needs of business growth?Does the L device run in 24 hours?Does the L require regular external processing?Is the L ready to acquire new equipment?If the brass case, even if the equipment running 24 hours can not meet the processing requirements, and have to rely on outward processing to make up, but also increase more equipment under consideration, then the factory first can try changing wire electrode with a much more efficient, may alleviate the contradiction between the processing and not imminent will you put too much money.In the same number of equipment, reducing the amount of external processing can also bring direct benefits.2. What are the working hours rates of the line cutting machines in the industry?This directly reflects the competitive power of the factory. Because hourly rates are often subject to industry averages, the amount of profit depends on the factory's ability to maximize productivity and reduce costs at the same rate level.3, the factory is satisfied with the quality of the processingnow?If a long time is the use of brass wire and processing quality problems occur frequently, which need rework, delayed delivery, lead to customer dissatisfaction, then put on the other wire electrode can improve the machining accuracy and surface quality? For different workpiece material, have you considered using different electrode wire to get better processing effect? This will also affect the processing costs and benefits of the factory.Next, we use a machining example to calculate the influence of the electrode wire on the machining cost:Test model: SODICK AQ325L (2000 factory)Test material: material SKH-9 steel, thickness 60mm, cutting length 29.99mmComparison of test results:Specification of galvanized wire electrode for brass wireA domestic brand hard wire electrode silk ZINCOElectrode wire diameter (mm) 0.20, 0.20Cutting times 33, cutting 1, repairing 2Dimensional accuracy, size error: 6 micron size error: 1 microns, machining accuracy improved significantlyThe straightness error is 4 microns and 2 micronsThe shape error of the sharp corners is obviously visible, the shape error is obviously improved, and the corner error is obviously reduced when the galvanized wire is not compensatedSurface quality (visual) deposition of copper has improved significantlyCutting thickness (mm) 6060Cutting length (mm) 29.99, 29.99Cutting area (mm2) 1799.4, 1799.4Processing time (minutes) 39.5, 27.3, 31% fasterProcessing speed (mm2/ minutes) 45.6, 65.9 cut, 1 repair, 2 average processing speedEconomic benefit calculation:Brass electrode wireWire walking speed (M / min) 13Wire length (M / h) 13x60=780Weight length conversion factor (g / M) 0.27 (for electrode wire of diameter 0.20mm)Wire consumption per hour (kg) 780x0.27/1000=0.211The actual discharge time per hour (hour) is 30 days x16 hours / day =480 hoursThe amount of silk consumed per month (kg) 0.211x480=101.28Unit price (yuan / kg) 30, 98Monthly electrode wire cost (yuan) 101.28x30=3038.40101.28x98=9925.44After using galvanized wire, increase the cost per month (yuan) 9925.44-3038.40=6887.04 yuan"Cut 1 to 2" (mm2/ minutes) 45.6, 65.9Monthly processing area (mm2) 45.6x480x60=131328065.9x480x60=1897920"1 2" processing rate of $0.045/ mm2Processing revenue per machine 1313280x0.045=59097.60 1897920x0.045=85406.40 per monthAfter deducting the increase of the cost of electrode wire, the monthly revenue per unit increased by85406.40-59097.60-6887.04=19421.76 yuan, an increase of 33%Explain1, the above calculations assume that the discharge time for processing time of 2/3, and processed parts of roughly the same, to "cut a repair two" as the main.2, the user can calculate according to their own circumstances, although the results are not the same, but according to our communication with dozens of users in Guangdong that, for processing a sufficient amount of users, revenue will increase.Through the above example can know, although the test used galvanized brass electrode than the unit price of 2 times,However, as the machining efficiency is increased by 31%, the machining benefit is actually a net increase. Therefore, the direct economic benefit of galvanized wire is obvious.To sum up, cheap brass is not the most economical choice, through high performance wire electrode design innovation and modern advanced cutting machine can achieve higher than the standard brass production efficiency, better price performance ratio.Therefore, different processing, please use different electrode wire.。