The error of a wire EDM machine refers to the difference between the finished workpiece and the expected value at the end of the wire EDM process. This difference may stem from machine tool inaccuracies, material deformation, calculation errors, or machine tool calculation and control errors, including:
1. Calculation errors: These are due to human error, and can be verified, proven, and detected early. Examples include premature rounding, repeated use of irrational numbers with insufficient digits (such as in multi-tooth shapes), and confusion between decimal degree systems and degree-minute-second systems.
2. Machine tool control errors: These occur very rarely because modern machine tool control systems are highly tested and technologically mature. They will not accept human-caused errors, and if they do, they can be verified or checked during pre-processing. Errors accumulated from multiple rotations and translations can also be detected during zero-point checks.
3. Material Deformation: As long as you have good operating habits, you should rehearse after calculation, verify after input, zero the machine before starting work, and check the handwheel scale. If you are confident that you have not made any calculation errors and the machine tool has not gone astray, the only remaining issue is deformation. However, you need to carefully consider the causes of deformation and the ways to overcome it.
4. Machine tool accuracy: This usually refers to mechanical accuracy, which is the difference between the actual value and the theoretical value. The most direct causes of this difference are backlash, straightness, and perpendicularity. This difference should be within 0.005~0.02mm. This value is measurable and adjustable. With the current machine tool structure, it is easy to control this error value below 0.02mm, but very difficult to achieve below 0.005mm.
In addition to the above, during the use of online cutting machines, users also need to perform necessary maintenance and upkeep, including:
1. Check the switch knobs of the circuit system, turn on the AC regulated power supply, turn on the power switch first, then turn on the high voltage switch, and wait 5 minutes before connecting to the negative line.
2. Check the output data of the regulated power supply and whether the neon LED digital tube is normal. Input information for about 5 minutes and perform a trial calculation. Only after it is normal can processing begin.
3. The high-frequency power switch for wire EDM should be in the off position before processing. The high-frequency power supply can only be turned on while the molybdenum wire is running, and it should be maintained at 60-80 volts. The high-frequency power supply should be turned off before stopping the machine.
4. Coolant should be added during cutting. When the molybdenum wire comes into contact with the workpiece, the voltage of the high-frequency power supply and the electrohydraulic value should be checked to ensure they are normal. Processing should never be carried out under arcing conditions.
5. Do not touch the electrode wire or workpiece with your hands or any conductor. Do not touch switches or other electrical parts with wet hands.
6. In case of malfunction, the high-frequency power supply should be turned off immediately, the cause should be analyzed, and no other items, especially metal equipment, should be placed in the electrical box.
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