Wire-cutting Molybdenum Wire

Wire cutting molybdenum wire  characteristics：

1. Electrical characteristics:

Modern wire-cut power supplies place strict demands on electrode filaments. It needs to be able to withstand large cutting currents of more than 700 amps at peaks or more than 45 amps on average, and the energy transfer must be very efficient to provide the high-frequency pulsed currents required to achieve a high surface finish (0.2Ra or more). This depends on the resistance or conductivity of the electrode wire. Copper is one of the highest conductivity materials, and it is used as a benchmark for measuring other materials. Copper's conductivity is marked at 100% IACS (International Annealed Copper Standard), while brass's conductivity is 20%

2. Mechanical properties：

(1) Tensile strength: Tensile strength is a measure of the ability of a material to resist fracture when subjected to radial load. It is scaled by the weight that can be carried per unit cross-sectional area, such as imperial PSI (pounds per square inch) or metric N/mm2 (Newton/square millimeter). Copper is the material with the lowest tensile strength (245N/mm2), while molybdenum is the highest (1930N/mm2). The tensile strength of the electrode wire depends on the choice of material and various heat treatment and tensile treatment processes. Electrode wires are sometimes divided into "soft wires" and "hard wires", each with its own strengths for different devices and applications.

(2) Memory effect: This is directly related to the "soft" or "hard" of the electrode wire. The soft wire does not have the memory ability to recover to a straight line when it is drawn off the shaft, so it cannot be used for automatic threading, but this has no effect on cutting because the tension is added to the electrode wire during processing. Soft wire is suitable for equipment with upper and lower guide nozzles that cannot be tilted for large slope cutting of more than 7 degrees. Hard wire is the best choice for an automatic threading machine, and because of its high tensile strength, its ability to resist the jitter of the wire caused by the current and flushing force during cutting is strong.

(3) Elongation: Elongation is the percentage of the change in the length of the electrode wire due to tension and heat in the cutting process. The elongation of soft wires can be as large as 20%, while hard wires are less than 2%. When the soft wire is processed in slope, the electrode wire with high elongation can ensure the geometric accuracy of the bevel, and the vibration generated by the softer electrode wire when sliding in the guide nozzle is also smaller. However, after the electrode wire enters the cutting area, the soft wire shakes more than the hard wire, so it must be considered in compromise.

3. Geometric properties：

In the early days of the development of in-line cutting technology (1969 to the mid-1970s), almost no research was done on electrode wires, using copper wires on off-the-shelf motors and cables. Today, high-efficiency and high-precision wire cutting machines require electrode wires to have geometric characteristics with extremely small errors. The final process of electrode wire manufacturing is to use multiple gem drawing dies to obtain a smooth, excellent roundness, and a wire diameter tolerance of +/-0.001mm. On the other hand, there are also some electrode wires that are deliberately designed to have a relatively rough surface, which can increase the cutting speed.

4. Thermal physical properties：

The thermophysical properties of the electrode wire are the key to improving cutting efficiency. These properties are determined by the proportion of alloy composition or the selection of the base core. Melting point: The melting point of the electrode wire is an important indicator. Due to the mechanical movement of the electrode wire through the guide nozzle, as well as factors such as flushing force and discharge, the electrode wire is jittery when cutting. This will cause an infinite of mini-short circuits, slowing down the cutting process. If the electrode wire can be lost at the outer diameter when working, it can prevent or reduce the short-circuit effect by the gap facing the direction of the cutout. At the same time, its void in the direction of the back to the incision helps to improve the flushing effect and can better remove processing debris. The loss of the outer diameter of the electrode wire does not affect the machining accuracy, because the new electrode wire is constantly being fed. This is one of the two properties of a material that metallurgists consider when studying the flushing properties of electrode wires. Gasification pressure: A large amount of heat is generated when the EDM is cut, and some of the heat is absorbed by the electrode wire, which reduces the cutting efficiency. If too much heat is lost on the electrode wire, the electrode wire will fuse due to overheating. Therefore, the surface of the electrode wire needs to be able to be gasified rapidly, and the thermal energy is released to the workpiece while the electrode wire is cooled. After the material is heated to the melting point, it will vaporize, generating a gasification pressure. Materials with low melting points are more likely to vaporize. Another characteristic of the electrode wire is the low melting point and high gasification pressure, which can help blow the waste residue away from the cutting seam. This is another characteristic that a good washdown electrode wire should have. When electrode filaments and workpieces are gasified rather than melted at the cutting surface, gas is produced instead of molten metal particles. This, in turn, improves the flushing process, as there are fewer particles to flush away.

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