How is the price for wire EDM machining determined?
Release date:
2022-05-07
Wire EDM with medium-speed wire feed is also a reciprocating wire-cutting machine, but its mechanical principles differ fundamentally from those of slow-speed and unidirectional wire-cutting machines. In essence, it is a high-speed wire-cutting machine. Consequently, the price of medium-speed wire-cutting machines should not be excessively high. Of course, this is not to dismiss medium-speed wire-cutting machines.
Wire EDM machines with medium‑speed wire feed are also reciprocating wire‑cutting machines, but their mechanical principles differ fundamentally from those of slow‑feed and unidirectional wire‑cutting machines. In essence, they are a type of high‑speed wire‑cutting machine. Consequently, the price of medium‑speed wire‑EDM machines should not be excessively high. Of course, this is not to dismiss medium‑speed wire‑EDM machines altogether. Mid‑to‑high‑end models perform well, and even lower‑priced mid‑range units can be regarded as fast‑feed wire‑EDMs that allow tool‑reconditioning. It is precisely due to unreasonable marketing practices and immature technology that the status of medium‑speed wire‑EDM machines has been unduly exaggerated. Some people even claim that replacing or surpassing slow‑feed wire‑EDM machines is undesirable.
In the early years, the price of medium‑speed wire EDM was relatively low. Due to the immaturity of high‑frequency technology and limited advances in machine‑tool design, repairs could be carried out simply by using the base of a fast‑wire EDM machine equipped with a control cabinet. Medium‑speed wire EDM is an upgraded version of high‑speed wire EDM and does not yet match the performance level of slow‑wire EDM. Although the consumable costs of slow‑wire EDM are significantly higher, its cutting accuracy and stability still make it a worthwhile choice. If the price of a 400‑stroke medium‑speed wire EDM were to approach 200,000 yuan, customers would likely opt for a slow‑wire EDM instead. Meanwhile, medium‑speed wire EDM machines are becoming increasingly mature, as evidenced by their steadily stabilizing prices.
Can wire EDM with medium-speed wire threading achieve automatic wire threading? This question has puzzled everyone since its inception. Particularly in recent years, as labor costs continue to rise, the appeal of automated wire threading has grown ever stronger. Automatic wire threading is a key feature of slow‑wire EDM machines. Such projects require substantial government support and financial backing from large corporate groups, and they must be approved at the national level. However, for various reasons—combined with the relatively modest profit margins in both medium‑speed and high‑speed wire EDM—the available resources are simply insufficient to sustain research on such a large‑scale initiative. At present, only a handful of companies receive significant support, making the research and development of slow‑wire EDM machines exceedingly challenging.
Of course, this serves as a warning for the future. In the market, this era calls for the emergence of automated threading systems. At present, several companies have begun R&D efforts, but most are only equipped with semi‑automatic wire‑feeding mechanisms. Automated threading systems remain unpatented.
The automatic wire‑threading system presents significant challenges. First, the molybdenum wire is very stiff and tends to bend when clamped. How can the bent tip be straightened to enable automated threading? Which principle should be employed—pneumatic cylinders or screws? Should an air‑brush be used, or hydraulic pressure? Furthermore, mid‑speed wire EDM machines employ a reciprocating wire‑feeding mechanism, requiring the molybdenum wire to be reused in a continuous reciprocating cycle. This substantially increases the complexity. Once the wire is clamped with a screw, how can the clamp be released automatically? And after threading, the wire must be re‑clamped automatically. This paper proposes converting the wire‑feeding roller’s cutting motion to a unidirectional feed. If successful, the transition feed roller would transform the wire’s reciprocating motion into a unidirectional feed, bringing the system much closer to slow‑feed wire EDM and opening up new possibilities for research into automated wire‑feeding systems. Moreover, this approach would significantly enhance both the stability and surface finish of mid‑speed wire EDM.
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