Wire guide for LS-WEDM ---a key component for precision machining

    Lower-speed wire cutting technology is an indispensable precision processing method in modern manufacturing. Its high efficiency and high precision make it widely used in mold manufacturing, aerospace, medical equipment and other fields. As an important part of the lower speed wire cutting machine tools, the performance and quality of the wire guide directly affect the processing accuracy and efficiency.

    Structure of wire guide

    A. Integrated lower-speed wire cutting wire guide

    1. Composed of metal (body), high-precision diamond pieces , ruby (ceramic) pieces .

    2. There is a through hole longitudinally on the metal body, and there are steps in the through hole. High-precision diamond pieces and ruby (ceramic) pieces are inlaid on the steps in the through hole. The center of the diamond piece is a wire guide hole.

    3. A ruby (ceramic) piece is installed on the upper and lower ends of the high-precision diamond piece. There is a trumpet-shaped guide hole in the center of the two upper and lower wire-threading guide sections. The small end of one trumpet-shaped guide hole is spliced at the upper end of the wire guide hole of the high-precision diamond piece, and the small end of the other trumpet-shaped guide hole is spliced at the lower end of the wire guide hole of the high-precision diamond piece. This forms an upper and lower two-way horn-shaped hole. The horn-shaped holes are conducive to the success rate of automatic wire threading.

    The integrated lower speed wire cutting wire guide is inlaid with diamond pieces. Because of its high hardness and good wear resistance, it can maintain accuracy during long-term processing and is widely used in high-precision processing fields. The hole shape and inner hole size of the diamond piece directly affect the positioning accuracy and stability of the brass wire.

    Commonly used item numbers:

    Suitable for Sodick machine tools：0206109、3081423、0206107、3081000、3080990、3081423

    Suitable for Mitsubishi machine tools： X052B627G64、X052B627G63、X052B609G64、X052B609G63 X053C834G53、X053C834G54、X052B243G61、X052B243G65

    Suitable for Agie Charmilles machine tools：200431122、100430586、200431112、100432511

    Suitable for Fanuc machine tools：A290-8110-X715、A290-8092-X716、A290-8092-X705、A290-8092-X706

    B. Split lower-speed wire cutting wire guide

    It is usually composed of two gemstone blocks, left and right. After the left and right gemstone blocks are pressed together by a cylinder, a threading hole is formed in the middle.

    Commonly used item numbers:

    Suitable for Sodick machine tools： 3081771、3080629、3080061

    Suitable for Makino machine tools： 6EC80B403、6EC80B404、6EC80B405

    Split lower speed cutting wire guides are usually composed of gemstone blocks, whose hardness and wear resistance are lower than diamond pieces, so their service life is relatively short. In addition, during the production process of the wire guides, matching grinding holes are required, so there is no interchangeability, and the manufacturing cost is relatively high.

    The main function of the wire guide

    The wire guide plays a vital role in the lower speed wire cutting process.

    1. Guarantee cutting accuracy: The wire guide accurately guides the movement of the brass wire to ensure that the brass wire remains stable during the cutting process, thereby ensuring cutting accuracy. The high hardness and high wear resistance of diamond sheets can maintain accuracy for a long time and reduce errors.

    2. Improve cutting efficiency: The peripheral nozzle of the wire guide can spray coolant to cool the brass wire and workpiece, reduce the high temperature caused by continuous discharge, reduce thermal deformation, and thereby improve cutting efficiency. At the same time, the working fluid can also wash away the fine waste produced in the gaps between the workpiece during the cutting process, keeping the cutting area clean and reducing discharge instability.

    3. Extend the service life of brass wires: Precision grinding and polishing of the inner wall of the wire guide and reasonable horn-shaped hole guidance can reduce the surface damage and breakage of the brass wire.

    4. Improve processing stability: The smooth inner hole and accuracy of the wire guide directly affect the stability of the processing process. High-quality wire guides can remain stable during high-speed cutting, reduce vibration and deflection, and improve processing stability.

    Maintenance and maintenance of wire guide

    In order to ensure the performance and service life of the wire guide, regular maintenance and upkeep are essential. The following are some maintenance and maintenance suggestions for the wire guide:

    1. Regular cleaning: Clean the inner hole of the wire guide regularly to remove waste and dirt generated during the cutting process and keep the inner hole of the wire guide clean and smooth.

    2. Check wear: Regularly check the wear of the inner hole of the wire guide, especially the wear of the diamond eye mold. Especially when cutting too large a taper, if serious wear is found, it should be replaced in time to ensure cutting accuracy.

    3. Up and down transposition: If the upper and lower wire guides are the same, the upper and lower wire guides can be transposed regularly, because relatively speaking, the wear degree of the lower wire guide is greater than that of the upper wire guides, ensuring that the continuous movement trajectories of the brass wire in the inner hole do not overlap.

    4. Choose the appropriate wire guide: For different mold materials, different processing precisions, different thicknesses, and different processing tapers, choosing the appropriate wire guide can effectively reduce the cost of use while ensuring the processing quality.

    Conclusion

    As a key component of precision processing, the performance and quality of lower-speed wire cutting wire guide directly affects the processing accuracy and efficiency. Understanding the structure, function, type and key role of wire guide in the processing process will help us better select and use wire guide and improve processing quality and efficiency. At the same time, regular maintenance and upkeep can extend the service life of the wire guide, reduce processing costs, and create greater economic benefits for the enterprise.