Common Problems and Countermeasures in Slow Wire EDM

Common Problems and Countermeasures in Slow Wire EDM

01 Broken wire

1) Poor discharge condition

Countermeasure: Lower the p-value; however, this approach will reduce processing efficiency.

2) The hot and cold water faucets must not face each other.

Countermeasure: Reduce the P-value and inspect the upper and lower spray nozzles for damage; replace any damaged nozzles promptly.

3) The conductive resistor block is severely worn or excessively dirty.

Countermeasure: Clean, rotate, or replace the conductive block.

4) The wire is too dirty, causing filament scratching.

Countermeasure: Clean the guidewire component.

5) Tension is too high

Countermeasure: Reduce the tension of the metal wire, especially when cutting with a taper.

6) Quality management issues related to electrode wire and workpiece materials

Countermeasure: Replace the electrode leads and reduce the P and I values until continuous wire feeding is achieved.

7) Waste wire from the spool overflows and comes into contact with the machine tool or the floor, causing a short circuit.

Countermeasure: Return the spilled waste filament to the waste filament bin and clean the bin promptly.

8) Insufficient cooling water for the conductive block

Countermeasure: Clean the cooling water circuit.

9) The wire was snapped at the reel.

Countermeasure: Check the compression ratio of the receiving roller; the standard value is 1:1.5 to 1:1.6, and inspect the lower guide roller bearing.

10. The conductor is running unevenly, and the balance wheel exhibits significant vibration.

Countermeasure: Adjust wire speed and tension.

02 Low processing efficiency

1) Single-board processing reduces the p and i values.

Countermeasure: Adjust the Z-axis and, whenever possible, employ veneer‑based machining.

2) The process sequence file is incorrect.

Countermeasure: Select an appropriate machining sequence file based on the processing requirements.

3. Workpiece deformation; perform repair, cutting, and machining without moving the workpiece.

Countermeasure: Optimize the production process to minimize material deformation.

4) Selected the ACO adaptive system function.

Countermeasure: When the cutting condition is stable, ACO can be disabled.

5) There are many corners, and a corner‑cutting strategy is employed.

Countermeasure: Appropriately reduce the cornering strategy.

6) Die trimming: the main cutting operation is not speed‑controlled, while the edge‑trimming speed is reduced.

Countermeasure: During die repair, set a reasonable speed limit for the primary cutting operation to prevent excessively rapid changes in cutting speed and ensure that the remaining material is adequately removed.

7) The main cutting efficiency can be reduced compared to the previous level.

Countermeasure: Perform timely maintenance on the machine tool.

03 The surface has silk-like marks.

1) Deformation caused by the workpiece material or internal impurities

Countermeasure: Arrange the process steps appropriately or switch to a different material.

2) The guidewire section is excessively dirty, and the conductive block shows severe wear.

Countermeasure: Perform timely maintenance on the machine tool.

3) The flushing condition is poor.

Countermeasure: Inspect the upper and lower spray nozzles; if they are damaged, replace them with new ones.

4) The working fluid is too dirty.

Countermeasure: Clean the storage tanks and water tanks, and replace the working fluid.

5) Insufficient cooling water for the conductive block

Countermeasure: Clean the cooling water circuit.

6) Wire feed is unstable, and the balance wheel vibrates significantly.

Countermeasure: Adjust wire speed and tension.

7) Repair and cut short-circuit rollback

Countermeasure: Adjust and increase UHP.

8) There is vibration near the machine tool.

Countermeasure: Improve the machine tool’s external environment.

9. The liquid temperature is too high, or the temperature difference from room temperature is excessive.

Countermeasure: Use a refrigerator to control the liquid temperature and maintain an appropriate room temperature.

04 Workpiece with a concave center and bulging sides, and with varying diameters at the ends.

1) The workpiece has a concave center.

Countermeasure: The Ssoll values of the primary and trimming parameters can be reduced.

2) The workpiece is bulging in the middle.

Countermeasure: Increase the target values of the primary cutting and trimming parameters.

3) Straight workpiece with a tapered end

Method 1: Add taper compensation

Method 2: Adjust ccon (based on the main program plane j, adjust the size of the reference plane)