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Introduction to Wire Cut

How It Works

Basic Principle:

  1. A thin, electrically charged metal wire (usually made of brass or molybdenum) acts as an electrode.
  2. The wire moves slowly across the workpiece, creating small electrical discharges (sparks) between the wire and the material.
  3. These sparks erode the material, gradually cutting through it along a pre-programmed path.

Key Components:

  1. Wire Electrode: The cutting tool (thin wire) that conducts electricity.
  2. Workpiece: The material to be cut (must be conductive).
  3. Dielectric Fluid: A fluid (e.g., deionized water) that flushes away debris and maintains electrical insulation.
  4. CNC Controller: Guides the wire’s movement based on a digital design (e.g., CAD files).

advantages

  1. High precision and accuracy (tolerances as tight as ±0.001 mm).
  2. No physical contact between the wire and workpiece, reducing tool wear.
  3. Capable of cutting extremely hard or brittle materials.

Types of Wire Cut

  1. Slow Feeding Wire Cutting: Uses a single, non-reusable wire for high-precision cuts (common in precision machining).
  2. Fast Feeding Wire Cutting: Recycles the wire for faster, lower-cost cuts (suitable for rough machining).

Applications

  1. Cutting complex shapes in molds, dies, and aerospace components.
  2. Machining hard materials that are difficult to cut with traditional tools.
  3. Creating precise slots, holes, and contours in electronics and automotive parts.