Improper Process Parameters:
Improper current, speed, or pulse parameters can easily cause molybdenum wire breakage during machining:
1. Excessive Current: Too high a peak current or uncontrolled short-circuit current can cause the molybdenum wire to overheat, especially noticeable when machining hard materials.
2. Uneven Wire Feed Speed: Too high a speed will cause wire jitter, while too slow a speed will lead to chip buildup. It’s best to keep the speed below 10m/s.
3. Incorrect Pulse Parameters: An excessively large pulse width can cause concentrated discharge, burning out the molybdenum wire; too small an interval will hinder chip removal.
Electrode Wire Quality or Condition:
Problems with the molybdenum wire itself directly affect its lifespan:
1. Material Defects: Inferior molybdenum wires lack tensile strength, have grooves on the surface, or have uneven diameters, making them prone to breakage during operation.
2. Failure to Replace in Time: Over time, the molybdenum wire will thin; a diameter drop from 0.18mm to 0.125mm necessitates replacement. 3. Tension and Wire Feed Control: Excessive tension easily leads to wire breakage, while insufficient tension causes vibration. Uneven wire winding or incorrect wire stop position can also cause wire vibration.
Workpiece Material Characteristics:
Risks of wire breakage due to different materials:
1. High Hardness/Thickness Workpieces: High-strength alloys or workpieces thicker than 100mm cannot remove etched material, easily causing arcing.
2. Special Issues with Aluminum Parts: Aluminum is soft and prone to oxidation. During processing, aluminum oxide can adhere to the molybdenum wire and get stuck in the grooves of the conductive block.
3. Internal Material Defects: Non-conductive impurities in the workpiece or uneven heat treatment can easily deform and break the molybdenum wire during cutting.
Machine Tool Abnormalities:
Equipment malfunctions can directly lead to wire breakage:
1. Wear of Guide Rollers and Conductive Blocks: Damaged bearings or excessively deep grooves in the conductive blocks increase friction and cause wire jamming.
2. Wire Storage Drum Issues: Failure to turn off the high-frequency power supply during reversal can burn out the molybdenum wire; misalignment of the drum bodies can easily cause wire stacking.
3. Malfunction of the working fluid system: Too high a concentration results in poor chip removal; too low a concentration leads to insufficient cooling; insufficient flow rate can cause the molybdenum wire to overheat.
4. Failure of the guide system: If the radial runout of the guide wheel exceeds 0.002mm, or the axial runout exceeds 0.005mm, the molybdenum wire will deviate and break.
Post time: Apr-02-2026