Feb 13, 2020 Viewed: 119 Tag: machining  

What are the steps in EDM?

I. Analysis and review of drawings

Analyzing the drawings is a decisive first step in ensuring the quality of the workpiece and the comprehensive technical indicators of the workpiece. Taking the punching die as an example, when digesting the patterns, we must first pick out the workpiece patterns that cannot or cannot be easily processed by EDM. There are roughly the following:

1, the surface roughness and dimensional accuracy requirements are high, the workpiece can not be manually ground after cutting;

2, the workpiece with a narrow slit smaller than the diameter of the electrode wire plus the discharge gap, or the workpiece with rounded corners formed by the electrode rig derrick discharge gap is not allowed at the corner of the figure;

3. Non-conductive materials;

4. Parts with thickness exceeding the wire frame span;

5. The workpiece whose processing length exceeds the effective stroke length of the xy carriage and which requires higher accuracy.

6. In accordance with the conditions of the wire cutting process, careful consideration should be given to surface roughness, dimensional accuracy, workpiece thickness, workpiece material, size, fit clearance and thickness of punched parts.

Programming considerations

1, Determination of die clearance and transition circle radius

2. Reasonably determine the die clearance. The reasonable selection of the die clearance is one of the key factors related to the life of the die and the burr size of the punched parts. The die clearance of different materials is generally selected in the following range:

3. Soft punching materials, such as copper, soft aluminum, semi-rigid aluminum, bakelite, red cardboard, mica, etc. The gap between the convex and concave dies can be 10% -15% of the punching thickness of the hard punching materials, such as For iron sheet, steel sheet, silicon steel sheet, etc., the clearance between male and female die can be 15% -20% of blanking thickness.

This is the actual experience data of some wire cutting punching dies, which is smaller than the large gap dies popular in the world. Because the surface of the wire-cut workpiece has a melted layer with a brittle structure, the larger the processing electrical parameters, the worse the surface roughness of the workpiece, and the thicker the molten layer. With the increase of the number of die punches, the crisp and loose surface of this layer will be gradually worn away, and the die gap will gradually increase. Reasonably determine the radius of the transition circle. In order to improve the service life of general cold stamping dies, transition circles should be added to the line, line circle, and far intersections, especially at small angle corners. The size of the transition circle can be considered according to the thickness of the blanking material, the shape of the die and the required life, and the technical conditions of the punched part. As the punched part is thicker, the transition circle can also increase accordingly. Generally can be selected in the range of 0.1-0.5㎜. For the 3D mesh technology forum, the transition circle is thin for the punched material, the die fit clearance is small, and the punched part is not allowed to increase. In order to obtain a good convex and concave die fit clearance, a transition circle is generally added at the corner of the figure. Because the electrode wire processing trajectory will naturally process a transition circle with a radius equal to the electrode wire radius plus a single-sided discharge gap at the inner corner.

4. Calculate and write processing programs

When programming, you should choose a reasonable clamping position according to the situation of the ingredients, and determine a reasonable starting point and cutting route. The cut-off point should be taken at the corner of the figure, or at a place where the convex tip can be easily removed. The cutting route is mainly based on the principle of preventing or reducing mold deformation. Generally, it should be considered to make it easier to cut the graphics near the side of the clamping.

5.Procedure paper and proofing tape for processing

After making the paper tape according to the program sheet, you must proofread the program sheet and the prepared paper tape one by one. After entering the program into the controller with the calibrated paper tape, you can try to cut the template. You can directly process the simple and sure workpiece. . For molds with high dimensional accuracy requirements and small clearances between convex and concave dies, thin materials must be used for trial cutting. The precision and clearance can be checked on cutting parts. If it is found that it does not meet the requirements, it should be analyzed in time to find out the problem, and the procedure can not be formally processed until it is qualified. This step is an important part to avoid scrapping the workpiece.

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