The characteristics of simple medium wire cutting are briefly summarized as follows:
1) Multiple cutting can be achieved
A significant difference between simple medium-speed WEDM and high-speed WEDM is that it can achieve multiple cuts, improving the surface quality of the workpiece and meeting the needs of the workpiece, thereby expanding its application range. For example, after three cuts, the surface roughness of a medium-speed WEDM machine tool reaches Ra ≤ 1.2μm.
2) Small electrode wire loss and energy saving
To achieve multiple cuts while ensuring machining efficiency, the cutting speed during roughing must be increased, which requires close cooperation with the pulse power supply. To this end, based on the development of power electronics technology, the pulse power supply of the medium-speed wire cutting machine has been improved and the current limiting resistor has been eliminated. This not only improves the performance of the pulse power supply but also saves energy.
Currently, the cutting speed of medium-speed wire pulse power supplies is close to 200mm²/min. The average speed of multiple cuts (for example, three cuts) can reach around 60-80mm²/min. Moreover, they achieve extremely low electrode wire loss. Therefore, some are called intelligent high-frequency pulse power supplies.
3) Intelligent control system
Medium-speed wire cutting mostly uses an industrial PC to form an integrated programming control system. Combined with the process database, the system can provide processing conditions to achieve high-speed processing, ensure quality, and simplify operation.
For example, after the user inputs the processing conditions (material, thickness, etc.) and process parameters (surface roughness, etc.), the system can provide appropriate electrical standards (pulse width, pulse interval, no-load voltage, processing voltage, processing current, etc.), as well as servo feed speed, electrode wire speed, etc. for each processing, and make appropriate responses during the processing.
Therefore, the control system requires close cooperation between the pulse power supply and the machine tool electrical system. Some people also call this type of machine tool an "intelligent multi-speed wire-cut cutting machine tool."
4) Variable frequency speed regulation can be achieved
To meet the varying requirements of each cut, the wire feed speed can be adjusted. The medium-speed wire-cutting machine utilizes AC variable frequency speed regulation, replacing relay control circuits with electronic logic circuits. This also facilitates interface with the control system and facilitates wire feed speed control. The use of variable frequency speed regulation also reduces the commutation impact of the wire feed motor, helping to maintain wire electrode stability.
5) High mechanical precision of machine tools
To ensure effective multiple cuts, the machine tool must have high repeatability, which places certain demands on the bed, guide rails, and other components. Appropriate structures and materials must be selected, linear guides must be used, and the feed system must employ gapless gear pairs or motor-driven backlash elimination to maintain machine tool accuracy and durability. Various measures are also taken to ensure wire electrode stability.
In addition, the Medium wire cutting machine has also developed new working fluids and new filtration systems to meet processing and environmental protection requirements.
Medium wire cutting is a new type of machine developed in recent years. It has great advantages in processing some workpieces with small thickness. It has the advantages of high cost performance of fast wire cutting and good processing quality. At present, medium wire cutting has a good development momentum.
Technical Specifications:
| parameter | unit | DK7732 | DK7740 | DK7750 | DK7763 | DK7780 |
| Work surface size | mm | 430×680 | 560×850 | 760×1150 | 760×1150 | 930×1320 |
| Workbench travel | mm | 320×400 | 400×500 | 500×630 | 630×800 | 800×1000 |
| Maximum processing thickness | mm | Adjustable wire rack up to 350 | Adjustable wire rack up to 450 | Adjustable wire rack up to 500 | Adjustable wire rack up to 600 | 900 |
| Maximum load weight | kg | 300 | 450 | 700 | 1000 | 1000 |
| Maximum molybdenum wire diameter | mm | ≤0.25 | ≤0.25 | ≤0.25 | ≤0.25 | ≤0.25 |
| Processing accuracy | mm | ≤0.015 | ≤0.02 | ≤0.02 | ≤0.02 | ≤0.02 |
| Processing roughness | mm | ≤2.5 | ≤2.5 | ≤2.5 | ≤2.5 | ≤2.5 |
| Wire feeding speed | m/s | 11.6 | 11.6 | 11.6 | 11.6 | 11.6 |
| Maximum efficiency | mm²/min | 100 | 100 | 100 | 100 | 100 |
| Host dimensions | mm | 1200×1600×1600 | 1300×1700×1680 | 2250×1800×2050 | 2250×1800×2050 | 2050×2300×2100 |
| Packing box size | mm | 1250×1650×1660 | 1400×1800×1750 | 2300×1850×2100 | 2300×1850×2100 | 2100×2500×2300 |
| Gross weight | kg | 1200 | 1600 | 3000 | 3300 | 5500 |
| net weight | kg | 1000 | 1500 | 2800 | 3100 | 4500 |
| Total power of electrical appliances | kw | ≤1.5 | ≤1.5 | ≤1.5 | ≤1.5 | ≤1.5 |
| taper | ° | ±3~±6 | ±3~±6 | ±3~±6 | ±3~±6 | ±3~±6 |
| Taper thickness | mm | Maximum thickness 100 | Maximum thickness 100 | Maximum thickness 100 | Maximum thickness 100 | Maximum thickness 100 |
Simple Medium wire cutting machine: Comprehensive Guide for Maintenance, Upgrades, and Troubleshooting
The Simple medium wire cutting machine is a versatile industrial tool widely used in manufacturing, electronics, and metalworking. Known for its precision and efficiency, this machine simplifies the wire cutting process while maintaining high productivity. This guide provides in-depth information about fault repair, upgrade solutions, maintenance tips, and common issues, helping operators and engineers maximize machine performance.
Introduction to Simple Medium Wire Cutting Machine
Key Features and Applications
Maintenance Tips for Longevity
Common Faults and Troubleshooting
Upgrade Solutions and Performance Optimization
Frequently Asked Questions (FAQs)
Conclusion
A Simple Medium Wire Cutting Machine is designed to cut wires of medium gauge efficiently with high precision. Unlike complex CNC machines, this model focuses on simplicity and ease of operation, making it suitable for small to medium-sized production environments. Its design emphasizes:
User-friendly interface
High cutting accuracy
Low maintenance requirements
Cost-effective operation
These machines are often employed in the production of electrical components, jewelry, small mechanical parts, and other applications requiring precise wire cutting.
| Feature | Description |
|---|---|
| Cutting Capacity | Handles medium-gauge wires, typically 0.5mm to 6mm |
| Cutting Accuracy | ±0.1mm depending on material and thickness |
| Motor Type | AC servo motor or stepper motor for smooth operation |
| Interface | Digital control panel with programmable cutting lengths |
| Safety | Overload protection, emergency stop, and protective covers |
Electrical wiring and cable processing
Jewelry making and metal crafting
Automotive wire harness production
Electronics component assembly
Industrial prototyping
These machines are ideal for businesses looking to increase efficiency while minimizing operator intervention.
Proper maintenance ensures that the machine performs reliably over time. Regular checks, lubrication, and cleaning are essential to prevent unexpected breakdowns.
Inspect cutting blades for wear and sharpness.
Clean the machine surface and control panel.
Check electrical connections for loose wires.
Lubricate moving parts according to the manufacturer’s instructions.
Verify calibration and alignment of cutting guides.
Inspect belts, pulleys, and motors for signs of wear.
Test the emergency stop and safety features.
Inspect control boards and sensors for dust accumulation.
Perform a trial cut to ensure cutting accuracy is maintained.
Pro Tip: Always use manufacturer-approved lubricants and replacement parts to maintain warranty validity and ensure machine longevity.
Even simple machines can experience issues. Understanding common problems and their solutions helps reduce downtime.
| Fault | Possible Cause | Solution |
|---|---|---|
| Machine not starting | Power supply issue | Check power connection and circuit breaker |
| Inconsistent cutting length | Sensor misalignment or calibration error | Realign sensors and recalibrate the machine |
| Blade not cutting properly | Blade dull or material mismatch | Replace blade or adjust cutting parameters |
| Motor overheating | Overload or insufficient lubrication | Reduce load, allow cooling, lubricate bearings |
| Error codes on display | Faulty wiring or software glitch | Inspect wiring, reset or update firmware |
Blade Dullness: Always keep a spare set of blades ready. Using a dull blade may cause inaccurate cuts or damage the wire.
Sensor Issues: Dust or debris on sensors can trigger false errors. Clean sensors regularly.
Motor Problems: Avoid overloading the machine beyond its rated capacity to prevent motor burnout.
As production demands grow, upgrading your wire cutting machine can enhance efficiency and expand capabilities.
High-Precision Blades – Improve cutting accuracy and reduce material wastage.
Servo Motor Upgrade – Offers smoother operation and more precise control.
Enhanced Safety Guards – Adds extra protection for operators in busy workshops.
Firmware Updates – Ensures the latest features and bug fixes are implemented.
Programmable Cutting Patterns – Allows batch processing of multiple wire sizes.
Connectivity Options – Integration with MES (Manufacturing Execution Systems) for better production tracking.
Optimize feed speed based on wire material to reduce wear.
Regularly update cutting parameters for different wire gauges.
Train operators on best practices to minimize handling errors.
Q1: What wire materials can this machine cut?
A: Typically copper, aluminum, steel, and certain alloys, depending on blade type.
Q2: How often should I replace the cutting blade?
A: Blade replacement frequency depends on wire material and daily usage. Heavy use may require replacement every 2–4 weeks.
Q3: Can the machine operate continuously for long shifts?
A: Yes, but it is recommended to take short breaks to allow motor cooling and reduce wear.
Q4: How do I ensure accurate cutting length?
A: Regular calibration and proper sensor alignment are essential. Use the digital interface to program precise lengths.
Q5: Are spare parts readily available?
A: Most medium wire cutting machines use standard blades, belts, and motors, which are easily sourced from manufacturers or distributors.
The Simple Medium Wire Cutting Machine is an essential tool for businesses requiring precision and efficiency in wire processing. By adhering to proper maintenance routines, addressing faults promptly, and considering upgrades for enhanced performance, operators can ensure reliable operation and a long service life.
Optimizing usage, combined with careful attention to troubleshooting and preventative maintenance, maximizes both productivity and ROI. Whether for electrical, industrial, or crafting applications, this machine remains a versatile and dependable choice.
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