1. How to achieve no line marks at the entry point?
(1) Use arcs for entry and exit of the outer shape;
(2) For inner holes: You can enter from the sharp corners, and the originally closed hole can be changed to an open hole; and the entry line of each cut is set at a different position (try not to set overcutting).
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2. How to make corner clearance (angle cleaning), what are the methods?
(1) Graphic angle cleaning;
(2) Compensation angle cleaning. Graphic angle cleaning is to process the graphics in advance and draw the angle cleaning; compensation angle cleaning is to add a very small R angle at the concave sharp corner, about 0.09mm (0.25mm line), so that when wire cutting, due to the small R angle, it will cause overcutting, and the purpose of angle cleaning can be achieved.
3. How to prevent deformation?
(1) To prevent deformation, the material must have no internal stress, especially the internal stress of quenched materials is large, so it must be tempered and stress relieved;
(2) Prevent in wire cutting process.
1) Choose the right starting position and support position. If you choose an inappropriate place, the support part of the material will become fragile after roughing, resulting in deformation; if you choose a place where the support part is relatively strong after roughing, it is right;
2) Make more supports. Especially when cutting punches, inserts and other shapes, if you encounter large or long workpieces, you should make several supports instead of one, which can effectively prevent deformation;
3) When cutting shapes, if the wire feed is deformed, the wire cutting will be greatly improved when punching through the wire hole.
4. How can the hole or shape of high-thickness materials be processed with the same size at the top, middle and bottom?
(1) Increase the wire speed and increase the wire tension slightly;
(2) When repairing the first cut (forming cutter), repair it several times, that is, repeat the first cut (because this cut is mainly for shaping, and the following is for smoothness);
(3) If it is convex or concave, most machine tools can adjust it in the electrical parameters (generally by adjusting the servo voltage SV);
(4) If the cut is conical (one end is large and the other end is small or vice versa), it can be corrected with cone compensation, that is, add a taper in the program (generally 0.002mm).
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5. How to do chipless processing with slow wire cutting, and what are the methods?
(1) Some wire cutting software has this function, which directly winds the coil in the hole;
(2) When programming, cut several times and use compensation to control. This method is more flexible, because if you find that the cutting speed is too slow or not ideal, you can change the compensation amount at any time to make corrections.
6. What are the methods for wire head processing? What should I do with a small punch?
(1) When cutting the shape, after the knife is trimmed, plug the copper sheet around and drip glue. Be careful not to drip too much. If too much glue is dripped, it will cause a short circuit. Finally, cut and trim the support part. This method is generally not recommended for small or large workpieces. Too little glue dripping will cause a short circuit. Too large workpieces will fall after cutting due to their own weight;
(2) That is, secondary clamping. For larger or batch workpieces, re-clamp and trim the support part. For batch small workpieces, you can cut the jig hole, which will effectively improve efficiency.
7. When cutting precision terminal molds, what should be done to ensure accuracy and position?
When cutting precision molds, especially templates, the whole roughing must be performed first, that is, all holes must be cut first without trimming. Then perform surface fine grinding, because the template surface will be slightly deformed during roughing, and finally all are finely trimmed.
8. Male and female molds are shared, and stripping plates are shared. How to calculate the angle, what should be paid attention to when programming?
Common use of male and female molds: (one-knife cut compensation amount X2-single-side gap)/(plate thickness-male mold blade-female mold blade) inverse sine. It should be noted that in general, the cut is a reverse cone.
Common use of internal and external stripping: There are two forms
1) Stepped type (mostly used);
2) Angle control, which is similar to common use of male and female molds, but without a straight body.
