In recent years, the rapid advancement of machining technologies has significantly boosted the development of wire-cut EDM, making it a key precision manufacturing method. Particularly, slow-feeding wire cutting has become an essential technique in mold and machine tool industries, enhancing both processing efficiency and quality.
**Development and Application of Electrode Wire Technology**
The evolution of wire-cutting technology is closely tied to the progress of electrode wire technology. Modern slow-moving machine tools are designed with the performance of the electrode wire in mind, and breakthroughs in this area often lead to innovations in wire-cutting equipment. From the early use of oxygen-free copper wires to today’s composite wires, the journey of slow-wire cutting has transformed from low efficiency and poor quality to high efficiency, high accuracy, automation, and professional production.
China's wire-cutting technology evolved from fast-moving and medium-stranded wires to the widely used low-speed wires, largely due to the gradual introduction of foreign advanced techniques. Since the 1970s and 1980s, galvanized electrode wires became popular, alongside brass, molybdenum, tungsten, and composite wires (with inner steel cores and outer copper layers), offering diverse options for users.
The actual slow-wire cutting technology entered China in the early 1990s, initially adopted by foreign-owned companies in the Pearl River Delta. At that time, non-ferrous metal processing was still underdeveloped, and raw materials were heavily imported, which slowed down the growth of wire-cutting technology in China before the 20th century.
After 2000, as China improved its smelting and machining capabilities, electrode wire technology began to develop more rapidly. The country's accession to the WTO further increased the variety of electrode wires imported, leading to confusion among users about the best choice. Selecting the right electrode wire is crucial for improving processing quality, machine efficiency, and reducing labor costs.
While Western countries have advanced toward high-speed and high-quality EDM, China remains at a lower developmental stage. Although more advanced electrode wires are now available, many users still rely on standard brass wires, limiting the full potential of their machines.
Some users even invest in high-performance wire saws but continue using ordinary brass wires, unaware of the impact of wire selection on performance. However, as user expertise grows and slow-wire cutting becomes more widespread, it has been observed that galvanized or composite wires can enhance efficiency and improve workpiece accuracy.
Since 2000, more users have started experimenting with high-performance brass and galvanized wires, realizing that different wires yield better results under various conditions. This shift has helped dispel the misconception that all electrode wires are made of brass, and Chinese companies have begun developing and producing their own specialized wires.
**Electrode Wire Characteristics**
The adoption of new technologies involves stages of imitation, absorption, digestion, and innovation. From the original H65 brass (65% copper, 35% zinc) to higher zinc content alloys like H63 and H62, it became clear that zinc plays a significant role in the cutting process. Zinc has a much lower boiling point than copper, allowing it to vaporize quickly during discharge, improving flushing and removing debris effectively.
However, when zinc content exceeds 40%, the material becomes brittle, making it unsuitable for small-diameter wires. As a result, new types of electrode wires with enhanced properties have emerged.
According to current domestic and international research, electrode wire materials must possess the following characteristics:
1. **Mechanical Properties**: The wire must withstand tension and impact during discharge. Weak materials can cause vibration, resulting in uneven cuts and multiple lines.
2. **Gasification Characteristics**: Efficient heat dissipation is essential to prevent the wire from being blown out during high-temperature discharges.
3. **Physical Properties**: Melting point and composition affect cutting speed and efficiency.
4. **Geometric Characteristics**: Dimensional accuracy and stability are critical for precise cutting.
5. **Electrical Properties**: The ability to handle high pulse currents improves surface finish and cutting performance.
**Classification of Electrode Wires**
Today’s electrode wires combine these five features and include additional properties like high strength and extensibility. They are categorized based on usage and processing conditions:
1. **Ordinary Brass Wire**: A copper-zinc alloy with limited cutting speed, prone to breakage and powdering.
2. **Galvanized Electrode Wire**: Coated with zinc, providing stable discharge and smoother surfaces. Mainly produced in Europe.
3. **Plated Electrode Wire**: Thicker coating for faster cutting, currently only available abroad.
4. **Diffusion Annealed Wire**: Porous structure enhances flushing, but has low tensile strength.
5. **Steel Core Wire**: High-strength core suitable for difficult materials like graphite and silicon.
6. **Fine Wire Electrode**: Ultra-thin wires for small angles, often replaced by piano wire.
7. **Piano Wire**: Made from high-carbon steel, offers good strength and is cost-effective.
**Wire Breakage Problem**
Despite advancements, many users in China still rely on just two types: brass and galvanized wires. Misunderstandings about wire breakage often lead to incorrect assumptions about wire strength rather than toughness. Discharge corrosion pits on the wire surface are the real cause of breakage.
Flushing plays a vital role in EDM, helping remove debris and dissipate heat. Poor flushing can reduce gasification effectiveness and damage the wire.
**Cheap Electrode Wire Issue**
Over 95% of electrode wires in China are made from common brass containing 60–65% copper. With copper shortages and rising prices, some manufacturers use recycled scrap, introducing harmful impurities that weaken wire performance and increase breakage risk.
These impurities can cause internal structural inconsistencies, reducing wire toughness and leading to frequent breaks. Users often blame machine performance or operator skill, not recognizing the impact of low-quality wires.
**Conclusion**
When selecting electrode wires, consider the model requirements, processing conditions, material hardness, surface quality, and consumable quality. Also, assess water quality, machine performance, and the specific advantages of each wire type. Choosing the right electrode wire ensures optimal cutting efficiency, precision, and long-term reliability.
Our graphic design team can transform your brand from concept to reality. We use the environmentally friendly label which can be washed off by water, so that the label can be wash off from the plastic packaging easily.The plastic materials can go in the recycling process clearly. And the water washable label can enter into the environmental protection recycling system more cleanly. There is always one brand label that we can achieve.
Fragile Sticker,Waterproof Stickers,Name Tag Stickers,Custom Stickers Cheap
Jiangmen JiuTai Plastic Product Co.Ltd , https://www.sequoiaent.com