5-axis Control Servo Wire EDM Machine
5-axis control servo wire EDM machine is a five-axis CNC large-tapered middle speed edm wire cut machine. It realizes five-axis CNC four-axis linkage servo control. It adopts “one-piece” design, the electromechanical structure is more stable, and the covering area is smaller. This kind machine’s working principle is to use the continuously moving molybdenum wire as the electrode, and perform pulse spark discharge on the workpiece to remove metal and cut the molding. Suitable for high precision taper processing, high precision parts processing etc.
Benefits of 5-axis Control Servo Wire EDM Machine
Results in Minimal Burr Formation
5-axis control servo wire EDM machine excels at cutting hard and delicate materials without harming cutting tools or distorting material surfaces or edges. Its continuously moving wire ensures an accurate, burr-free finish, eliminating the need for additional deburring or cleanup.
Increased Productivity
The advanced control and automation features of a 5-axis servo wire EDM machine enable continuous and efficient machining, leading to higher throughput. The machine can handle more complex jobs in less time, boosting overall productivity.
Flexibility
A 5-axis control servo wire EDM machine allows for the machining of complex geometries and intricate features from multiple angles. This flexibility is critical for producing parts with challenging contours, undercuts and complex shapes.
Improved Surface Finish
The 5-axis control servo wire EDM machine provides precise movement and positioning of the wire, leading to a superior surface finish and higher precision. This is especially important in industries like aerospace and medical device manufacturing, where tight tolerances and high-quality finishes are required.
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Why Choose Us
Construction Area
The company currently has a modern factory of more than 20 acres in the high-tech zone of Suzhou City, Jiangsu Province, with a construction area of more than 20,000 square meters, more than 80 employees, and engineers account for 30%.
Our service
24-hour service. The after-sales service in different countries is mainly provided by agents from different countries. If customers need to repair themselves, we can provide relevant spare parts.
Our Certificate
The company has passed the "ISO9001" quality management system certification, won the national "high-tech enterprise", "provincial private technology enterprise", and is the director unit of "China Machine Tool Industry Association Special Processing Machine Tool Branch".
Years Of Experience
Engaged in electric machining research and development services for over 20 years. Fully CNC mirror EDM was successfully developed and put into production. Introduce modern enterprise management mode (enhance soft power).
Traditional EDM machine is slower than its wire EDM machine counterpart because it requires the development and shaping of electrodes, often made from highly conductive materials like copper or graphite. In contrast, the setup for 5-axis control servo wire EDM machine is quicker, as it starts as soon as the wire is in place, making it ideal for rapid production needs.
Additionally, it achieves greater accuracy because the wire itself acts as the electrode, capable of cutting materials as thin as 0.004 inches. This capability makes it particularly effective for machining complex parts. The wire, acting as a thin, heated electrode, allows for a smoother machining process compared to traditional methods where electrode shapes and sizes can affect the finish.
How can a 5-axis Control Servo Wire EDM Machine Achieve Ideal Smoothness?
Reduce the pulse width and peak current appropriately, that is, reduce the size of the etching pit. The guide wheel and bearings maintain good accuracy and smooth operation, reducing wire shaking and jumping, and minimizing the displacement of the wire movement trajectory. Maintain appropriate tension on the molybdenum wire, and adjust the guide wheel and feed block so that the tension in the working area remains unchanged when the wire goes up and down.
The thread should not be too tight, and the water should not be too fresh. New water is definitely beneficial for cutting efficiency, but the cutting smoothness is not new water. Add a clamp on each side of the workpiece that is too thin, so that the directional stripes are buffered within the clamp range. The stability, accuracy, good tracking fidelity, and unobstructed crawling of XY movement are also extremely important. Maintain stable and loose frequency conversion tracking. Cutting again or multiple times with appropriate allowance can have a beneficial effect on dimensional accuracy and smoothness by scanning the cutting surface once when the cutting amount is very small.
Carbide: Tungsten carbide is frequently machined for cutting tools, dies, and wear-resistant parts.
Titanium: Used in aerospace, medical, and high-performance automotive components due to its strength-to-weight ratio and corrosion resistance.
Superalloys: Such as Inconel, Hastelloy, and other nickel-based alloys, which are essential for high-temperature applications, especially in the aerospace and power generation industries.
Stainless Steel: Various grades of stainless steel are machined for components that require corrosion resistance and strength.
Aluminum: While softer, aluminum is often machined for components in the aerospace, automotive, and electronics industries.
Copper and Brass: Used for electrical components, connectors, and intricate parts where conductivity is important.
Graphite: Commonly used for electrodes in EDM processes.
What Types of Wire are Used in 5-Axis Control Servo Wire EDM Machines?
Brass Wire
Brass wire is the most commonly used wire in wire EDM due to its good electrical conductivity, reasonable cost, and ease of use.
Coated Brass Wire
Coated brass wire has a thin layer of zinc or other materials to enhance cutting performance.
Copper Wire
Copper wire is another common choice for wire EDM. It is highly conductive and provides good cutting performance.
Zinc-Coated Wire
The zinc coating reduces wear on the wire and improves electrical discharge characteristics, making it ideal for high-speed applications and machining tough materials.
Molybdenum Wire
Molybdenum wire is used in applications that require very high tensile strength and precision, such as micro-machining and cutting hard materials like carbide.
Tungsten Wire
Tungsten wire has the highest tensile strength and melting point of all the wires, making it ideal for demanding applications.
Aerospace Industry
Aerospace industry parts, including turbine blades and landing gear components, rely on an excellent surface finish and must be highly accurate. Manufacturers have been using the 5-axis control servo wire EDM machine process for many years with exceptional results.
Automotive Industry
Automotive parts often have complex shapes and are produced from hard materials. Because of this, they prefer 5-axis control servo wire EDM machines that do not rely on mechanical forces to make their parts. The 5-axis control servo wire EDM machines applies to creating holes, cavities, and custom parts like bumpers, dashboards, and car doors.
Medical Industry
5-axis control servo wire EDM machines produce complex and accurate parts for all medical fields, including optometry and dentistry. Because the wire’s diameter determines the cut’s size, the 5-axis control servo wire EDM machine can add tiny features to parts like dental implants and syringe components without endangering their structural integrity.
Electronics
With the 5-axis control servo wire EDM machine, microelectrodes used in microelectronics for circuitry and sensors can be produced with efficiency. These microelectrodes frequently need very tight tolerances to perform properly in electronic equipment. It is a great option because it can produce these components with micron-level accuracy.
Mold
In mold and die making, 5-axis control servo wire EDM machines are used to create highly detailed and complex molds for plastic injection molding. The multi-axis capability allows for the machining of deep cavities, undercuts, and intricate features that are critical for producing high-quality molded parts.
How to Ensure the Cutting Quality of 5-axis Control Servo Wire EDM Machine
Managing Kerf and Surface Finish
Achieving optimal kerf width and floor end is critical for ensuring excellent of cuts in wire EDM machine. The kerf, or the material eliminated for the duration of the cutting manner, immediately impacts the precision of the very last product. Manufacturers can control kerf width via cautiously controlling parameters together with voltage, pulse length, and flushing fees, hanging a balance between cloth removal and dimensional accuracy.
Additionally, great-tuning those parameters contributes to achieving a superior floor end, minimizing the want for secondary completing tactics. The meticulous control of kerf and floor finish is a cornerstone in turning in super, ready-to-use additives with wire EDM machine.
Minimizing Wire Breakage
Wire breakage can significantly impede reaching first-class cuts in wire EDM machine. Several factors make contributions to wire breakage, such as immoderate tension, inadequate flushing, and suboptimal cord alignment. Implementing right tensioning techniques, maintaining constant flushing situations, and making sure precise twine alignment thru normal upkeep are critical steps in minimizing the chance of cord breakage.
By addressing those factors, producers can enhance the reliability of the wire EDM machine method, decreasing interruptions and safeguarding the integrity of the reduce, ultimately making sure the manufacturing of incredible rapid prototyping components.
Maintaining Dimensional Accuracy
Dimensional accuracy is paramount in meeting stringent production quality. Wire EDM machine excels in generating complex shapes with high precision, however keeping dimensional accuracy calls for meticulous attention to material. Calibration of system parameters, monitoring environmental situations, and the use of advanced metrology equipment for in-manner dimension make a contribution to reaching and maintaining dimensional accuracy.
Regular machine renovation, which include examining and changing worn additives, is similarly critical. By prioritizing these factors, producers can continually deliver portions that adhere to precise dimensional requirements, upholding the highest satisfactory requirements in wire EDM machine.
Reasons for 5-axis Control Servo Wire EDM Machine Wire Breakage
Current Density
There are several key factors involved when determining what caused the wire breakage. The first and sometimes the obvious is the current density: the amount of current on any given surface area. When that exceeds the physical limitations of electrical current flowing on the surface of the wire, it creates enough heat to melt the wire.
Dielectric Flushing
Another cause of wire breakage can be the flushing of the wire. This is the first thing we usually reach to adjust and the easiest to see immediate results. Bad flushing can come from poor head placement, usually too far away from the workpiece. If moving the head closer is not an option because of clamps or other obstructions, then increasing the volume of water could resolve the situation.
Power Application
The point at which power is applied to the wire is a point of wire break that is sometimes overlooked. You will notice that the wire will break at a point near the top surface of the part. This is caused by worn or misadjusted power contacts. By replacing or adjusting the contact plate, the breakage will stop immediately.
Poor Maintenance
Poor maintenance is not as common of a cause but can be just as important to consider and one of the more difficult to pinpoint. This will usually be in the wire transport system and can be dirty wire rollers, worn guides, small bits of broken EDM wire, misadjusted wire tension or bad water conductivity. A check of the wire path from roller to scrap bin is best done by a careful inspection of every component in order.
How to Maintain 5-axis Control Servo Wire EDM Machine
Cleaning and Inspection
Clean the machine's working area, guides, and wire paths regularly to remove debris, chips, and wire fragments. Inspect components like the wire guides, drive belts, and pulleys for wear and tear, and replace them as needed to ensure smooth operation.
Check and Adjust Wire Tension
Proper wire tension is crucial for accurate cutting and reducing wire breakage. Regularly check and adjust the wire tension according to the machine's specifications to maintain consistent performance and prolong wire life.
Lubricate
Ensure that all moving parts, such as linear guides, ball screws, and servo motors, are properly lubricated. Use the recommended lubricants and follow the manufacturer's guidelines to prevent friction and wear, which can impact the machine's accuracy and longevity.
Calibrate
Periodically calibrate the 5-axis control system to ensure precision in movement and positioning. This includes checking the alignment and synchronization of all axes to prevent any deviation from the programmed path, which can lead to errors in machining.
FAQ
As one of the leading 5-axis control servo wire EDM machine manufacturers in China, we warmly welcome you to buy discount 5-axis control servo wire EDM machine from our factory. All customized machines are with high quality and low price.
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