DK77 Series

CNC EDM Wire Cutting Machine

Operation Instructions

TAIZHOU RUITE MACHINERY EQUIPMENT CO., lTD

Please note:

1Before operation, you must read the machine tool manual!

2The machine tool must be reliably grounded during installation

Catalogue
Part I electrical
1、 Safety protection of machine tool electrical appliances.......... 1
2、 Operation of machine tool electrical appliances.................. 1
3、 Schematic diagram of operation panel of machine tool electrical
appliances.......................................................... 1
4、 Control principle of machine tool electrical appliances (refer to the
schematic diagram).................................................. 3
5、 Schematic diagram of installation position of electrical main board,
with marks.......................................................... 4
6、 List of electrical components................................... 6
7、 Schematic diagram............................................... 8

Part II machinery
1、 Purpose......................................................... 9
2、 Main specifications and relevant parameters of machine tool...... 9
3、 Overview of machine tool......................................... 9
4、 Lubrication system of machine tool............................... 11
5、 Control system of machine tool.............. .................. 12
6、 Machine tool cooling system...................................... 12
7、 Hoisting and installation of machine tool........................ 12
8、 Operation and adjustment of machine tool....................... 12
9、 Maintenance of machine tool..................................... 14
10. troubleshooting of machine tool............................... 15
11、 Machining process characteristics of machine tool............... 16
12、 Rolling bearing details........................................ 17
13、 Vulnerable parts.............................................. 18
14、 Packing list................................................... 18
Part I electrical
1、 Safety protection of machine tool electrical appliances
1 The design and manufacture of machine tool electrical appliances shall comply
with GB / ts2261-1996, "industrial machinery and electrical equipment Part I",
general technical conditions and "gbi3567 technical conditions for safety protection
of electrical spark machining machine tools".
2 The electrical equipment of the machine tool uses three-phase AC power supply,
and the voltage range is 380v10%.Through special design, the electrical appliances
of the machine tool can work at a slightly higher voltage, but the maximum voltage
shall not exceed 420v. If it is higher than this voltage, the normal and safe operation
of the machine tool cannot be ensured.
3 The electrical equipment of the machine tool is equipped with a protective
grounding circuit. Users should pay attention to the reliable grounding of the
machine tool to meet the requirements of the continuity of the protective grounding
line and ensure the personal safety of the operators.
4 The red emergency stop button is set on the electrical operation panel. In
case of emergency, the main power supply of electrical equipment can be quickly
disconnected, the rotation of wire storage cylinder can be quickly stopped, and the
pulse power supply will stop working at the same time.
5. energy consumption braking.Under any of the following conditions, the wire
storage Jane motor can brake quickly within 1-2s.
(1) When the power circuit or control signal is interrupted (i.e. power failure);
(2) When molybdenum wire is broken;
(3) At the end of processing;
(4) When the reversing failure of wire storage Jane exceeds the limit switch;
(2) In ~ (4) cases, the power supply of the wire storage drum motor can also
be cut off immediately;
6. overcurrent protection
A circuit breaker and fuse are connected at the incoming line of the electrical power
supply of the machine tool and in the lighting circuit for overcurrent protection.The
rated current of its circuit breaker and fuse shall be strictly required, and the
user shall not increase or reduce it at will, so as not to play a protective role.
7 This machine has bidirectional thyristor commutation, low noise, safety,
reliability and low consumption.
 8. end shutdown
At the end of workpiece processing or a command, the machine tool can cut off the
power supply of all electrical equipment controlling the machine tool at the same
time.

2、 Machine tool electrical operation sequence

1.Turn on the external power switch of the machine tool, and the machine tool
is powered on. At this time, the voltage indicated by the voltmeter is 380V ± 10%.
2.Press the button SB1 with light, hear the closing sound of AC contactor, power
on the machine tool, and all electrical appliances are in standby state.
3.Press the button switch SB2, if the wire has been loaded into the guide wheel,
the wire storage cylinder runs, and the wire conveying motor M1 works.
4.Press the button switch Sb3 and the water pump motor M2 will run.
5.If molybdenum wire is not installed at this time, E1 and E2 must be unscrewed
and then Sb4 must be pressed before the wire conveying motor can work (feed processing
can be carried out after completing steps 1-4).
6.Turn on the knob switch E1, automatically stop the brake immediately after
the wire is broken, turn on the knob switch E2, and cut off the power supply of all
machine tool appliances according to the computer control program after processing,
that is, the automatic duty function.

3、 Schematic diagram of electrical operation panel and rear panel of machine tool
 4、 Electrical control principle of machine tool (refer to electrical schematic
diagram of machine tool)
The electrical circuit of the machine tool includes water pump circuit, wire
conveying and automatic commutation circuit, automatic high-frequency circuit when
turning off operation or commutation, shutdown braking circuit and unmanned
automatic duty circuit.
1. turn on the emergency stop switch SPI, press the illuminated button SB1, the
AC contactor KMI, the coil is powered on, the power indicator L2 is on, the power
supply of the machine tool incoming control circuit is powered on, and the input
voltage range is required to be 380V + 10%
2.Power on converter C and transformer TC2.
3.Open 12 (on the operation panel).
4.Press button switch SB2.
A. The coil of AC contactor km2 is energized, the normally open contact km2 is
closed, and the wire conveying motor operates.
B. If the wire is installed into the guide wheel at this time, the small relay
KA3 is energized and the normally open contact KA3 is closed. At this time, the knob
switch E1 can be put on.
C. When processing is started in this way, turn on the knob switch E2 to realize
the automatic shutdown function, which can be automatically shut down after
processing.
E. The contactor km2 acts, the wire transport motor works, the wire transport carriage
and molybdenum wire move forward to charge the capacitor C1, preparing for the energy
consumption action of the wire transport motor M1.
F. When the wire plate impact block pressure range switch sq1-2, sq1-2 is normally
open and closed, the small relay ka2 is energized and closed, the commutation circuit
is controlled to make M1 rotate in the reverse direction, and the wire transport
carriage and molybdenum wire move in the reverse direction.
J. When the bump on the wire transport carriage travels q1-1 in the other
direction, sq1-1 is normally closed and disconnected, ka2 is released, and the motor
M1 rotates in the opposite direction again to complete a cycle.
5.When it is released from the coil of the storage machine 1, the energy
consumption braking is realized for the motor M1, and the wire conveyor stops running
immediately.
 6.The machine control circuit stops the motor M1 and brakes immediately to avoid
the tangle of molybdenum wire caused by wire breakage. Continue to use the remaining
molybdenum wire. At the end of processing, the small insulator KA3 is also powered
off, the release contact KA3 is disconnected, and KM1 is released to cut off the
power supply of machine tool electrical appliances and control cabinet, so as to
prevent the machine tool from continuing idle running at night or when no one is
present. The empty consumption of control cabinet is safe and energy-saving,That
is, the function of unattended.
7. KA1 and km2 are connected in series to disconnect the high frequency during
commutation. When shutting down the wire operation, the high frequency output can
also be turned off to avoid burning the copper wire.
8.Sq1-3 is a travel limit switch. Press the block to sq1-3 without permission,
disconnect the normally closed contact and cut off the main power supply. When the
capacitor C1 is discharged, the wire transport motor performs energy consumption
braking.
6、 List of electrical components of machine tool

Serial Model and

Code name quantity remarks
number specification

Wire conveying
1 M1 A07114380V 1
motor

Water pump
2 M2 AB-25380V 1
motor

KM1 KM2
3 AC contactor 3TB41-22E220V 2 Siemens
KM3

Intermediate
4 KA1 KA2 JQC-18FF 220V 2 OMRON
relay

Intermediate
5 KA3 JQC-3FF 5V 1 OMRON
relay

Emergency stop Red mushroom

6 SP1 LAY7 1
button head

2 red and 2
7 SP1-SP3 Control button LAY7 4
green

8 SQ1 Travel switch JW2-11Z/S 1

9 E1、E2 Knob switch LAY7 3 Black knob

10 SB1 Light switch LAY7 1 EL2 in green

11 voltmeter 44L1 450V 1

FU2 FU3 6A
12 Fuse 1
FU1 10A

Control
13 TC1 JKB-70W 1
transformer

Buffer
14 TC2 JKB-500W 1
transformer

15 EL1 Machine lamp 36V(40W) 1

Rectifier
16 V1 10A 1000V 2
diode
 17 2

Serial Model and

Code name quantity remarks
number specification

Bidirectional
18 V2-V5 41-700B
thyristor

19 V6-V10 diode IN4007

Electrolytic 4700/450V
20 C1
capacitor 6800/450

Winding
21 R1-R3 50W 5.1Ω
resistance

Winding
22 R4 20W 150Ω
resistance

23 R5-R8 resistance 2W 300Ω

24 R9-R12 resistance 2W 100Ω

25 C2-C5 capacitance 0.1UF/630V

Electrolytic
26 C6C7 470UF/50W
capacitor

Reversing
27 AP 130×eighty-seven
plate

28 DC6 Wiring base Td2506

Aviation
29 Z1 4Core p16
socket

Aviation
30 Z2 30Core p48
socket

Power supply
3core
socket
 Part II machinery

1、 Use
DK series CNC WEDM is composed of CNC machine, high-frequency power supply and
machine host.This product is suitable for processing various complex national metal
stamping dies, sample poles and parts with complex shapes with high precision, high
hardness and high shear in industrial departments such as electronic instruments,
household appliances, precision machinery, light industry and military industry.It
is a necessary machine tool in machining composition.
2、 Main specifications and relevant parameters of machine tool:

3、 Machine tool overview

WEDM technology has been widely used, and it shows one of the machining methods
that other machine tools are difficult to achieve.
The basic principle of WEDM is to process the workpiece by pulse discharge with
tool electrode. WEDM does not need to make forming electrode, and fine metal wire
(usually called electrode wire) is used as Ding electrode.The positive pole of the
pulse power supply is connected to the workpiece, and the negative pole is connected
to the electrode wire;The electrode wire moves back and forth at a certain speed,
and it constantly enters and leaves the discharge area;At the same time, liquid medium
is sprayed between the electrode wire and the workpiece.As long as the operator
effectively controls the speed and trajectory of the electrode wire relative to the
workpiece, he can cut the workpiece with the required shape and size.The trajectory
of workpiece movement is formed by the X and Y direction movement of the workbench
(two controlled stepper motors in the vertical and horizontal directions) on the
coordinate.
DK series CNC wire cutting machine host is composed of machine bed, workbench, wire
conveying device, wire rack, coolant tank, machine tool electrical appliances,
accessories and other components.It takes the bed as the base, and the workbench,
wire conveying device and wire frame are installed on the same base surface of the
bed.
The following are introductions:

1. Bed: the bed is a front casting, on which worktable, wire storage cylinder,
silver frame, lighting lamp, etc. are installed.
2. Worktable: the worktable is mainly composed of the middle worktable, the
middle carriage, the bead wire rod and the variable speed wheel tube. The quasi
transverse movement of the carriage adopts the sea moving guide rail structure, and
the worktable is manufactured by the stepping motor through the network and the
European wheel transmission society.Spider transmission has the advantages of high
precision, high efficiency and long service life.
3. Wire conveying device: the wire storage cylinder is composed of thin-walled
hollow cylinder.The motor drives the wire storage Jane to rotate through the
coupling,
At the same time, the reciprocating movement of wire winding Jane comes from the
lead screw after gear speed change to drive the carriage of wire conveying device.The
wire transport carriage adopts V-shaped track ball structure, and the oil tank is
filled with oil to make the carriage slide on the oil surface all the time, so as
to prolong the service life of wire transport.
A group of travel switches are used to control the frequent commutation of the
carriage of the wire storage drum, which has simple structure and sensitive action.
The left and right collision blocks are equipped with overload safety devices. When
the commutation of the travel switch fails, the current of the wire transport motor
is cut off.
4. Wire frame: molybdenum wire is like a closed conveyor belt, which is driven
by winding wire Jane to work back and forth. A row of wire wheels and a pair of leading
wheels are wrapped by molybdenum wire and follow-up.
 The wire frame part is composed of a column and an upper and lower line frame.
Loosen the fixing screws of the upper line frame and rotate the column screw
rod with a crank to make the
According to the requirements of the processing parts, the line rack will change
the span of the wire rack, the guide wheel will use the sealed structure to assemble
the human line rack, and the lower frame can release the fastening screws, and can
adjust the 6mm before and after, so that the molybdenum wire moves in the front and
rear direction, and is convenient for adjusting the vertical molybdenum wire.
5. The coolant tank water pump sends the working fluid to the processing area.
The sediment accumulates in the dirt box and must be cleaned regularly.DX-1
saponification solution for working coolant.
6. Accessory (mountain) fixture: Group fixture is used to fix flat or cylindrical
workpieces. It is of platen screw structure, and the fixture is fixed on the workbench
with T-shaped screws.
(2) Crank: used to rotate the wire storage cylinder and adjust the span of the
wire frame during wire winding.
(3) Wire tensioning wheel: used for manual tensioning of molybdenum wire.
4、 Machine tool lubrication system
The moving parts of the machine tool are lubricated manually and regularly.
Note: the hydraulic bearing of the guide wheel on the wire frame shall be replaced
with high-speed lubricating grease every two weeks.

number Refueling position Refueling time Refueling Lubricating

method oil

1 Cross feed rolling Once per shift Oil gun 32No. 1 oil
screw

2 Longitudinal feed Once per shift Oil gun 32No. 1 oil

rolling screw

3 Driving gears of silk Once per shift Oil gun 32No. 1 oil
storage drum

4 Screw rod nut Once per shift Oil gun 32No. 1 oil

5 Oil tank for supporting Once a month Fill 30No. 1 oil

plate of silk storage
cylinder
5、 Machine tool control system

number name Function

Left and right fork of travel Adjust the stroke of the upper support
1
switch plate of the wire storage drum

See the description of the electrical

2 Button board
system of the machine tool

Adjust the working fluid flow of the

3 Water valve
upper and lower nozzles of the wire rack

Horizontal and vertical moving Adjust the horizontal and vertical

4
handle of worktable position of the workbench

6、 Cooling system
In the process of cutting, molybdenum wire and workpiece need sufficient coolant.
The coolant tank is the output device to supply the pressure coolant in the slope
zone of the working area.The coolant is guided by the upper and lower nozzles and
brought into the original seam for cutting with the movement of molybdenum wire,
so that the adhesive particles and chips on the cutting surface are discharged from
the old seam, and the role of cooling molybdenum wire is achieved at the same time.
There are two knobs on the line frame, which are the adjustment switches of the
upper and lower nozzles respectively, which are used to adjust the flow of the upper
and lower nozzles.
7、 Hoisting and installation of machine tool:
1During the handling of the machine tool, try to avoid unauthorized attack and
fierce vibration.Lifting holes have been installed at the four corners of the upper
part of the bed for lifting. The length and angle of the lifting steel wire rope
should be appropriate. The contact between the lifting rope and the parts of the
machine tool should be avoided as far as possible. If necessary, soft objects can
be filled at the contact to avoid scratching the appearance and damaging the paint
surface and the accuracy of the whole machine.
2The CNC wire cutting machine installed on the machine tool is a precision machine
tool. Therefore, strong vibration source, strong electromagnetic flux field and
noise interference are not allowed around its work site, otherwise it will directly
affect its normal work. If the conditions of the work site are limited, shockproof
foundation can be used to isolate it from the source, and soft objects can be filled
in the shockproof trench to eliminate vibration.The texture of concrete foundation
requires pouring.The machine tool host, high-frequency power supply and CNC machine
shall be reasonably arranged on the foundation surface.The machine tool shall be
installed on the foundation so that it is in a natural horizontal position with the
help of the level regulator under the machine bed.The installation direction of the
machine tool shall make the operator face the natural light source as much as
possible.
3. service conditions of machine tool:
(1) The machine tool is a precision machine tool. The working area shall be kept
clean and isolated from external vibration sources, and strong electromagnetic field
nearby shall be avoided as far as possible.
(2) The working environment temperature is 20 ± 5C, and the relative humidity
is no more than 80%.
(3) When the voltage of the external power supply fluctuates greatly, the power
supply of the CNC machine must be connected to a special regulated power supply.
8、 Machine operation and adjustment:
1Preparations before shift:
(1) Start the power switch, let the machine run without load, and observe whether
its working state is normal.

● the controller must work normally for more than ten minutes;

● all parts of the machine tool shall work normally;

● the pulse power supply and machine tool electrical appliances work normally

without error;

● each travel switch contact acts sensitively;

● all inlet and outlet pipelines and valves of working fluid are unobstructed, the

pressure is normal, and the lift meets the requirements.

(2) Add more work

Generally, it is advisable to replace it every other week.
(3) Decide whether to change the electrode wire
2. adjust wire rack
 Use a square or electrode wire vertical corrector to correct the electrode wire
perpendicular to the worktable.
3. inspection workbench
Press the key on the keyboard of the controller to control the stepping motor,
manually rotate the vertical and horizontal handwheel of the workbench, and check
whether the stepping motor is sucked.Input a certain displacement to make the scale
rotate forward and reverse once respectively, and check whether the dial returns
to "0".
4. work clamp
(1) Fix the fixture on the workbench.
(2) When clamping the workpiece, use a dial indicator to align the datum plane
of the workpiece according to the requirements of the drawing to make it parallel
to the transverse or longitudinal direction of the workbench.
(3) Check whether the workpiece is set in the work line
(4) The workpiece and fixture shall not touch any part of the wire frame during
cutting.
(5) After the workpiece is clamped, all sundries on the worktable shall be
removed.
5. adjustment of guide wheel
When adjusting the guide wheel, it is necessary to keep the guide wheel rotating
flexibly without axial movement.When replacing the guide wheel, add high-speed
grease in the bearing.
6. Operation steps:
(1) Power on
Press the power switch to turn on the power.
(2) Input the machining program into the control machine.
(3) Kaiyunsi
Press the wire transport switch, let the electrode wire run empty, and check
the jitter and tightness of the electrode wire.If the electrode wire is too loose,
tighten the wire fully and evenly.
(4) Boil the water pump and adjust the spray amount.
When boiling the water pump, please turn the regulating valve to the closed state
first, and then turn it on gradually. Adjust the upper and lower spray columns to
contain the electrode wire, and the water column can shoot at the cutting area. The
water volume does not need to be too large.There is a drainage hole in front of the
bottom of the upper rack, which is often kept unblocked to avoid water in the upper
rack from seeping into the electrical box of the machine tool.
(5) Select electrical parameters of on pulse power supply
The user shall select the most suitable electrical parameters according to the
requirements for cutting efficiency, precision and surface roughness.When the
electrode wire cuts into the workpiece, please open the pulse interval. After cutting,
adjust the pulse interval when it is stable to make the processing current meet the
requirements.
(6) Turn on the control machine and enter the processing state.Observe whether
the pointer of the ammeter is stable during cutting, carefully adjust and avoid short
circuit.
(7) After processing, turn off the water pump motor first, then turn off the
wire conveying motor, and check whether the X and Y coordinates reach the end
point.Remove the workpiece at the end, clean and check the quality;Before reaching
the end point, check whether the program is wrong or the control machine is faulty,
and take remedial measures in time to avoid scrapping the workpiece.
There is a red emergency stop button switch on the electrical control panel and
control panel of the machine tool. In case of any accident during operation, press
this switch to power off and stop.
9、 Maintenance of machine tool:
Correct and reasonable adjustment and use and attention to the maintenance of
the machine tool can ensure the cutting accuracy of the machine tool and prolong
the service life of the machine tool. Therefore, the following requirements are put
forward:
1. The whole machine shall be kept clean frequently, and the worktable, fixture,
wire conveying parts and their metal natural color without surface treatment shall
be exposed.If it is shut down for more than 8 hours, wipe it clean and apply oil
to prevent rust.
2. Under the normal use of the machine, all transmission parts must be lubricated
according to the previous requirements.
3. The cleaning around the main wheel and wire row wheel of the wire frame
components is particularly important. It should be cleaned frequently with kerosene.
After cleaning, the dirty oil should not leak into the return tank of the workbench,
so as not to affect the service performance of the working fluid with the coolant
flowing into the coolant tank.
4. The guide wheel and its shaft follow the working parts, and the service life
is short. It depends on the service situation. Generally, it can be replaced in a
complete set within 2-3 months.
5. When the machine tool is in normal use, the coolant shall be changed once
a week.
6. The operators shall not leave the site. In case of wire breakage (the machine
tool has wire breakage shutdown protection device), the broken wire shall be cleaned
to avoid damaging the wire conveying device.
7. To master the performance of the machine as soon as possible and maximize
the efficiency of the machine tool, it is necessary to specify and fix the operation
and maintenance personnel.
10、 Troubleshooting of machine tool:

Serial Problems in
Causes Method of exclusion
number machining
1. The electrode wire is loose 1Tighten the electrode

or shaken. wire.

The workpiece 2. The vertical and horizontal 2Check and adjust the

surface has motion of the worktable is workbench and the wire

1
Obvious Silk unbalanced, and the motion storage cylinder.

Mark vibration of the wire storage 3Adjust electrical

Jane is large. parameters and frequency

3Cutting tracking is unstable. conversion parameters.

1. The electrode wire is loose. 1Tension the electrode

2. After long-term use, the wire.

accuracy of guide wheel bearing 2Replace the guide wheel

2 Shaking wire is reduced and the V-groove of and bearing in time.

guide wheel is worn. 3, adjust or replace the

3. The impact vibration of wire coupling of wire storage

storage Jane during Jane.4. Replace the

 commutation. electrode wire.

4. the electrode wire is not

straight.

1. The electrode wire is too 1Tighten the screw again.

loosely wound. 2Tighten the wire or

3 Pine silk
2. the use time of electrode replace the electrode

wire is too long. wire.

1. Large axial clearance of 1Adjust the clearance of

The guide
guide wheel. the guide wheel.
wheel jumps
2. Working fluid and electric 2Clean the bearing with
and screams,
4 corrosion enter the bearing. gasoline.
and the
3The precision of bearing is 3Replace the guide wheel
rotation is
reduced after long-term use, and bearing.
not flexible
resulting in wear.

1. The diameter of electrode 1. Replace the electrode

wire becomes thinner after wire.

long-term use.2. Severe 2. Check the causes of wire

chattering. shaking.

2. The working fluid supply in 3. Adjust the working

the processing area is fluid flow.

insufficient and the discharge 4. Select electrical

5 Broken wire of electric corrosion is not parameters correctly.

smooth. 5. Adjust the reversing

3. Improper matching between clearance of the carriage.

workpiece thickness and 6Cut people manually or

electrical parameters, remove oxide scale.

frequent short circuit.

4. Wire stacking is caused by

large reversing clearance of

 wire storage simple carriage.

5. There are impurities in the

workpiece material and oxide

scale on the surface.

1. The worktable is driven by 1Check and adjust all

vertical and horizontal lead links of transmission lead

screws, with poor positioning screw.

accuracy and large reverse 2Check and adjust the

clearance. verticality.

2. The vertical accuracy of the 3Replace or adjust the

longitudinal and transverse guide wheel and bearing.4.

Poor
guide rails of the workbench is Check and adjust the
6 working
poor.3. Guide wheel runout, controller or replace the
accuracy
large axial clearance and stepping motor.

serious wear of guide wheel

V-groove.

4The control machine and

stepper motor fail and lose

step, and the processing

program does not return to "0".

11、 Machining process characteristics of machine tool:

In order to improve the efficiency of wire cutting machine.Please pay attention

to the following points when using the machine tool:

1. Calculate the bench mark and compile the measurement program according to the

drawing size and the actual situation of the workpiece.However, it is necessary to

test the installation method and quality of the workpiece

The electrical level is straight, and a reasonable cutting position is selected.

2. According to the prepared program, punch the control tape with the punch

machine, and calibrate the punched paper tape. For workpieces with complex shape,
it is best to operate the control machine to make the machine run empty once, or

cut sheet test pieces to calibrate the prepared program one by one.

3. When clamping the workpiece, pay attention to the position and the moving range
of the workbench to make the machining cavity consistent with the requirements of
the drawing.For the workpiece with small machining allowance or special requirements,
the parallelism between the workpiece and the vertical and horizontal moving
direction of the worktable must be accurately adjusted to avoid scrapping the
workpiece due to insufficient allowance, and the initial vertical and horizontal
seat mark value of the worktable shall be recorded.
4. When machining concave die, discharge plate, fixed plate and some special
cavities, the electrode wire shall be threaded into the pre drilling of artificial
parts first.
5. We must be familiar with some particularity of WEDM Process, give full play
to the economic benefits of machine tool use, the main factors affecting the machining
accuracy of EDM and the specific measures to improve the machining accuracy.In
on-line cutting, in addition to the motion accuracy of the machine tool directly
affecting the machining accuracy, the change of the spark gap between the electrode
wire and the workpiece and the deformation of the workpiece also have an impact on
the machining accuracy that can not be ignored.
6. Machine accuracy
The accuracy of the machine tool has been fully debugged according to relevant
standards before leaving the factory, but the operator must still check and adjust
the accuracy of the machine tool when machining precision workpieces.
(1) Check the guide wheel: before processing, carefully check whether the
V-shaped groove of the guide wheel is damaged, and remove the electric corrosion
accumulated in the V-shaped groove.
(2) Check the driving clearance of the vertical and horizontal lead screw pair
of the worktable.Because frequent reciprocating motion will change the transmission
accuracy, before machining precision workpiece.Carefully check and adjust to meet
the corresponding standards before processing.
(3) The spark gap between electrode wire and workpiece is closely related to
material, cutting speed, coolant composition and other factors.
 ● the change of spark gap varies with the workpiece material, heat treatment

and cutting thickness.It is due to the different chemical, physical and mechanical

properties of materials and the different chip removal and deionization ability

during cutting.

● relationship between spark gap and cutting speed

Within the effective machining range, the cutting speed is fast, the spark gap
is small, the cutting speed is slow and the spark gap is large, but the cutting speed
must not exceed the corrosion speed, otherwise there will be a short circuit.If a
certain machining current is maintained in the cutting process, the voltage between
the workpiece and the electrode wire will be certain, and the spark gap will be certain.
Therefore, in order to improve the machining accuracy, try to achieve uniform
frequency conversion in the cutting process, basically stable machining current,
and constant cutting speed.
@Relationship between spark gap and coolant
The size of spark gap is affected by different coolant composition, different
resistivity, chip removal and deionization ability.Therefore, when machining
high-precision workpiece, we must measure the spark gap and program or select the
gap compensation.
7Measures to reduce workpiece material deformation.
(1) Reasonable process route
When wire cutting is the main process, the processing route of steel parts:
blanking, forging, annealing, mechanical finishing, quenching and tempering,
grinding, wire cutting and fitter repair.
(2) Selection of workpiece materials
The workpiece shall be made of materials with small deformation, good
hardenability and high yield limit. For example, alloy tool steels such as Cr WMN,
crl2mo and GCrl5 shall be used as the materials for concave convex die.
(3) Improve the quality of forging blank
The calcination shall be carried out in strict accordance with the specifications,
and the initial and final calcination temperatures shall be well controlled.
In particular, the high alloy tool steel shall also be carbon free
According to the segregation degree of chemical compounds, spheroidizing annealing
is required after calcination in order to crystallize and slightly reduce the
residual stress of heat treatment.(4) Pay attention to the quality of heat
treatment. During heat treatment and tempering, the process parameters shall
be reasonably selected, the specifications shall be strictly controlled, and
the operation shall be strict
Correct, the lower limit of allowable fire heating temperature shall be adopted as
far as possible, the cooling shall be checked, the tempering shall be timely,
and the upper limit of tempering temperature shall be adopted as far as possible
The time limit shall be sufficient to eliminate the residual stress generated after
heat treatment as far as possible.
(5) Reasonable process measures

● arrange the sequence of hot and cold processes correctly to eliminate the

stress caused by machining.

● when cutting the punch from the blank, it shall not be cut in from the outside.

Threading holes shall be made near the contour of the punch. At the same time, it

shall be noted that the cutting part shall not be too close to the periphery of the

blank. It shall ensure that the blank has sufficient strength, otherwise it will cause

the deformation of the cutter.

● the cutting starting point should be at the balance of the principal quantities

of the figure and at the junction of the two-stage wheel Gallery, so that the opening

deformation is small.

● when cutting large workpieces, a splint shall be added while cutting, or a

cushion block shall be used to cushion, so as to reduce the deformation caused by

the sag of the processed part.

 ● for small or slender workpieces, the factors affecting deformation are

complex. During cutting, trial method shall be adopted, cutting and measuring shall

be carried out at the same time, and the procedure shall be corrected at the same

time until the requirements of the drawing are met.

12、 Rolling bearing details:

Installation
number name model quantity Specifications
position

Single row
radial
1 D46105 4 workbench 25×forty-seven×twelve
thrust ball
bearing

Single row
2 radial ball D203 2 workbench 17×forty×twelve
bearing

Single row
3 radial ball D18 4 workbench 8×twenty-two×seven
bearing

Single row
Silk
4 radial ball D203 2 17×forty×twelve
transportation
bearing

Single row
Silk storage
5 radial ball D203 2 17×forty×twelve
cylinder
bearing

Single row
6 radial ball D25 12 Wire rack
bearing

Single row
7 thrust D8103 2 Wire rack 17×thirty×nine
bearing

13、 Vulnerable parts (non spare parts):

 Part name quantity Installation position

Guide wheel 3 Wire rack

Wire stopper 1 Wire rack

Incoming block 2 Wire rack

D25 bearing 6 Wire rack

Buffer sleeve 4 Coupling

14、 Packing list:

Serial
Packing contents quantity list
number

1 Machine host 1platform

2 Attached factory accessories 4 Table I

3 Attached factory spare parts 2 Table II

4 an instruction manual 1

Table I attached factory accessories:

Serial number name number

1 Rocking handle 1

2 Tightening wheel 1

3 fixture 1pay

4 Organic water shield 1pay

5 Bottom adjusting screw 4set

Table II spare parts delivered with the machine:

Serial number name number

1 Synchronous belt 1root

2 Buffer sleeve 4only

TAIZHOU RUITE MACHINERY EQUIPMENT CO., LTD
ADD: NO.327, Jiangzhounan Road, Hailing Zone, Taizhou,
Jiangsu, China, 225300
Wechat & Whatsapp: +8618852677068
Fax: +86-0523-86693596
Web: https://www.ruitewedm.com/