High-precision taper machining with wire EDM

One of the main features of WEDM is the ability to perform vertical, oblique or combination cuts. The table below lists the main areas of application where high precision taper machining is required.

Factors affecting the quality of taper machining In general, processing difficulty increases with the increase of the following factors:

* Change in tilt angle: the larger the angle, the more difficult it is to control the wire path and stability;

* The amount of change in the tilt angle when machining a single profile: When the angle changes in a single machining operation, it is difficult to ensure uniform surface quality and consistency of the geometric accuracy of the entire workpiece;

* Surface roughness: The higher the requirements for surface roughness, the greater the importance of geometric position and guiding accuracy;

* Dimensional accuracy: The higher the requirement for dimensional accuracy, the higher the requirements for precise correction of the wire path.

To overcome these negative factors, the following will find out the solution to the problem one by one:

1) Effect of the type of the wire electrode 2) a guide system 3) changes the angle 4) the geometric position of the wire electrode type correction 

The first is to select the appropriate electrode wire. As long as the processing slope exceeds a certain value, it is very important to select the electrode wire with high flexing ability. This type of wire, called "soft wire", typically has a tensile strength between 400 and 500 N/mm2, while the "hard" wire has a tensile strength of 900 N/mm2.

Compared to hard wire, soft wire of large elongation, so the wire can be held between the soft upper and lower guide wire impact linear state  system can guide the two The linear state between the guides depends mainly on the type of wire, and the stability of the wire during processing is also an important factor. The stability of the wire during the WEDM process is an extremely important factor, which requires the machine tool manufacturer to have a high level of manufacturing process. Shamir succeeded in solving this problem by developing a large arc radius guide based on a diamond-enclosed guide that minimizes wire deflection.

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