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Wire cutting is the use of moving metal wire ( molybdenum wire, copper wire or alloy wire ) as the electrode wire, and the pulse electric spark discharge between the electrode wire and the workpiece generates high temperature to melt or vaporize the metal to form a slit, thereby cutting the parts The processing method.

Main features of wire cutting :

Compared with traditional turning, milling and drilling processing methods, wire cutting has its own characteristics: [

( 1 ) Directly use 0.03-0.35 mm metal wires as electrodes, no specific shape is required, which can save electrode design and manufacturing costs;

( 2 ) Regardless of the hardness of the workpiece material, as long as it is a conductor or semiconductor material, it can be processed, and the electrode wire loss is small, and the processing accuracy is high;

( 3 ) It is suitable for the processing of small batches, complex shapes, single pieces and trial products, and the processing cycle is short;

( 4 ) In WEDM machining , the wire electrode and the workpiece are not in direct contact, and the effect between the two is very small, so the deformation of the workpiece is small, and the wire electrode and fixture do not need too high strength;

( 5 ) The working fluid adopts water-based emulsion, which has low cost and will not cause fire;

( 6 ) It is not suitable for processing large-scale parts with simple shapes, nor can it process non-conductive parts.

Main applications of wire cutting :

Processing molds;

Machining parts with fine structure;

Machining parts with complex shapes;

Processing hard conductive materials;

Trial production of new products;

Precious metal blanking.

WEDM ( Wire Electrical Discharge Machining Cut referred WEDM ), belong to the category electrical processing, the basic physical principle consisting of positive ions and electrons is accumulated in the field, and soon form a conductive ionized channel.

CNC wire cutting machine is composed of three parts: mechanical, electrical and working fluid system

Cutting process steps

Prepare workpiece blanks, clamping tools, measuring tools, etc. before processing. If it is necessary to cut a workpiece with an inner cavity shape, or the process requires processing with a threaded hole, the blank should be pre-made with a threaded hole, and then follow the steps below:

(1) Start the machine tool power supply to enter the system and prepare the processing program;

(2) Check whether there are any abnormalities in each part of the machine tool, such as the operation of high frequency, water pump, wire tube, etc.;

(3) Wire threading, threading, and vertical alignment;

(4) Clamping the workpiece and aligning;

(5) For the wire, establish the starting position of cutting;

(6) Start the wire feed, turn on the working fluid pump, and adjust the nozzle flow rate;

(7) Adjust processing parameters;

(8) Run the processing program to start processing;

(9) Monitor the processing process, such as wire feeding, electric discharge, working fluid circulation, etc. whether it is normal;

(10) Check whether the parts meet the requirements. If there are errors, they should be dealt with in time to avoid scrapping of processed parts

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what is etching?

Photo chemical etching (PCE), also known as photo chemical machining (PCM) or photo etching, is the use of photo-reactive resist to fabricate precision metal parts based on desired dimensions.

Photo etching is similar to other printing processes. It images part dimensions onto photo-resist coated metal, which is then developed and etched, resulting in the desired part. This process produces intricate parts with tolerances (as low as 0.01 mm) that would be otherwise unachievable with processing methods such as laser cutting, water-jet cutting, stamping, punching, or die-cutting.

Advantages of the Photo Etching Process

Chemical etching, or photo chemical machining, offers many advantages over other milling techniques may not be as accurate or economical. It:

Doesn introduce any sources of mechanical stress: Each part maintains the mechanical properties of the customer selected metal (or metal alloy).

Dissolves the unwanted metal via chemical reaction: burring, shearing deformation, and ablative deformation typically associated with other machining processes are avoidable.

Improves precision: Chemical etching can be used with materials as thin as0.0003 inches. Holes can be as small as 0.004 inches, while edge dimensions can be within 10% of a part thickness

Allows for high part quantities: Large volumes of parts can be put into production on short notice, which allows a higher degree of flexibility.

Supports greater part complexity: The photo chemical process can yield metal components with complex multi-dimensional characteristics; it can even create score lines so parts can be folded.

Lowers production costs: Tooling adaptations are easy to make, and a design change may cost only a couple hundred dollars, reducing the cost overhead for metal part prototyping and full production.

Cost Benefits

Metal etching is more cost-effective than other machining processes because it allows for more complex designs with intricate features. Increasing design complexity often doesn result in increased production costs. A faster processing time reduces costs as well. Many parts can be completed within a day. An etch rate of 0.0005 to 0.001 inches per minute is possible.

The process also eliminates rework, so project costs are centered only on the initial process. The ease and speed of designing tools also lower costs. Building, for example, stamping tools can take weeks and cost thousands of dollars. Maintaining them and addressing wear and tear can be costly as well. Production with photo chemical etching can be more cost-effective than stamping or punching.

With metal etching, part quality is improved. This makes your products more valuable and cuts out steps such as deburring, which is often costly and time-consuming. Chemical etching also supports more affordable mass production (as many as millions of pieces can be produced economically). Given the speed and accuracy of the process, customers can complete prototypes and get products to market faster, increasing profits.

Metals and Common Parts

United Western Enterprises, Inc. works with many metal alloys. These include several types of versatile, lightweight aluminum alloys. We also work with the purest copper alloys, as well as phosphor bronze, brass, and nickel silver (often used for RF shielding, but less costly than nickel plating with the same luster). Other materials include beryllium copper, nickel and nickel alloys, and a range of common stainless steel alloys suited for various parts and environments.

Many everyday parts can be produced with photo etching. These include circuit board components and electronic devices such as image sensors, attenuators, and parts for digital cameras and waveform samplers. EMI and RFI shielding, metal shims, apertures, encoder discs, springs, and contacts with different gauge metals can be made. Chemical etching works for everything from battery components and heat sinks to the production of medical imaging equipment, radar systems, and telescopes.

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