CNC deformation solution after wire cutting
Wire cuttinguses electric spark discharge to cut metal, and CNC machining uses computer-controlled machine tools to perform precision machining. Both are commonly used in mold making. If deformation occurs after wire cutting, it will directly affect the accuracy and efficiency of subsequent Cnc Processing, and even cause parts to be scrapped. Therefore,controlling deformation is crucial.
Based on the root causes of CNC machining deformation after mold steel wire cutting, corresponding solutions are proposed to reduce deformation and improve processing accuracy. By optimizing the process, material waste and processing losses can be reduced, and the rework rate can be reduced, thereby saving costs, improving efficiency, and enhancing corporate competitiveness.
⚡ Actual processing situation
Workpiece deformation after wire cutting: In actual processing, workpieces often bend, twist and other deformation phenomena after wire cutting; seriously affecting the accuracy and assembly of subsequent CNC processing.
Deformation quantification data: The amount of deformation is usually between 0.02-0.1mm, or even more serious. For precision manufacturing, such deformation is unacceptable, and effective measures must be taken to control it.
🔩 Material factors
Residual stress inside the material: Traditional tool and die steel may generate residual stress during processing; these stresses are released during wire cutting EDM and cutting processes, causing workpiece deformation.
Preliminary rough machining of the material: the stress generated by the material during the sawing process of the blank, such as large cutting area and insufficient cooling, but the sawing speed is slow, resulting in very little stress. The residual stress caused by the large cutting volume and fast speed during fine material milling and grinding.
⚙️ Wire cutting process factors
Thermal impact of electric spark discharge: During the wire cutting process, electric spark discharge will generate high temperatures, causing the formation of a heat-affected zone on the surface of the material; the mechanical properties of this area will change and deformation will easily occur.
Influence of cutting parameters: Cutting speed, pulse width, pulse frequency and other parameters will affect the energy density and heat input of the electric spark; unreasonable parameter settings will cause the heat affected zone to increase and deformation to intensify.
Effect of coolant: The flow, temperature and composition of the coolant will affect the cooling effect; insufficient cooling will lead to heat accumulation and increase the risk of deformation.
🖥️ CNC machining factors
Influence of cutting force: During CNC machining, cutting force will cause the workpiece to deform; especially for thin-walled, slender or poorly rigid workpieces, the deformation is more obvious.
Influence of clamping method: Unreasonable clamping method will cause uneven stress on the workpiece; thus causing or exacerbating deformation, special attention needs to be paid to the stability and reliability of the clamping.
Influence of cutting parameters: Cutting speed, feed rate, cutting depth and other parameters will affect cutting force and cutting heat; unreasonable parameter settings will lead to increased deformation.
🔧 Wire cutting optimization
(1) Choose low-stress wire cutting technology
Adopt low-stress wire cutting process and evenly and firmly clamp to avoid hanging pull force, reduce heat input and residual stress during the cutting process, and reduce the occurrence of deformation.
(2) Optimize cutting parameters
According to the material properties of different tool and die steels, parameters such as cutting speed, pulse width, and pulse frequency are optimized; the range and depth of the heat-affected zone are reduced, and parameter combinations are recommended.
(3) Adopt multiple cutting strategies
Adopt multiple cutting strategies to gradually release the stress inside the material; reduce the amount of deformation caused by one-time cutting and improve processing accuracy.
🎛️ CNC machining control
(1) Optimize the clamping method
Use a reasonable clamping method to ensure uniform stress on the workpiece; reduce deformation caused by clamping and improve processing stability. A clamping plan is recommended.
(2) Use reasonable cutting parameters
According to the material characteristics of tool and die steel, parameters such as cutting speed, feed amount and cutting depth should be reasonably selected; reduce cutting force and reduce the risk of deformation, and the recommended parameter range is recommended.
(3) Adopt layered cutting strategy
Adopt a layered cutting strategy to gradually remove material; reduce cutting force and cutting heat, and reduce the occurrence of deformation.
📌 Other auxiliary measures
(1) Early precautions
It is recommended that when pre-processing and milling of materials, especially slender and thin sizes, the clamping should be even and firm, and the cutting process should be consistent with CNC. Stress relief treatment should be carried out when necessary, which is also a preventive measure to avoid residual stress in the early stage.
(2) Heat treatment process optimization
Use reasonable residual stress relief tempering or aging treatment to release the residual stress inside the material;
To improve the stability of the material and reduce the sensitivity to deformation, stress relief treatment options are recommended.
(3) Pre-deformation compensation technology
By deforming the workpiece in advance, the deformation generated during wire cutting is offset;
Improve machining accuracy and achieve precise compensation.
(3) Online measurement and compensation
Online measurement technology is used to monitor the deformation of the workpiece in real time; based on the measurement results, the processing parameters are adjusted to achieve dynamic compensation and improve processing accuracy and efficiency.
