Development of electrode wires(CUT WIRE) for high-performance wire electro-discharge machining

摘要

Development of Electrode Wires ("CUT WIRE") for High-Performance Wire Electro-Disoharge Machining-Masatada Numano, Naoyuki Ohkubo, Hirokazu Sugawara, Yoshihiro Nakai and Kenji Miyazaki-In recent years, wire electro-discharge machining (WEDM) hasattracted considerable attention as a machining technique for materials with poor machining properties and ultra high-precision metal dies that are difficult to machine by conventional mechanical means. WEDM is designed to meet the market demand forimproved productivity and the optimum balance between high cutting speeds and the high levels of machining accuracy required to improve machining quality. Sumitomo Electric already produces the Cut Wire series for use in WEDM, such as SBS, SBG, SC, S, SS, and SG, and has developed another new range of electrode wires providing outstanding features meeting specific machining requirements. This report describes these new high-performance WEDM electrode wires.(1) SS Cut Wire for fine machining of thick materialsSince SS offers a 30-50% improvement in tensile strength at high temperatures, cutting precision has been greatly improved, with a 7% increase in cutting speed.(2) SG Cut Wire for high-precision machiningThe amount of zinc in the SG electrode wire has been increased to improve its discharge properties and conductivity. This has yielded excellent results, including a 16% increase in cutting speed and a 10% improvement in the quality of surface finishingwhile maintaining similar levels of cutting precision.(3) SZS Cut Wire for high-speed, high-precision machiningSZS is the Cut Wire made with a composite structure. It features improved discharge properties as well as a 40-60% increase in tensile strength at high temperatures. As a result, the machining speed has been increased by approximately 20% simply byreplacing the electrode wire with SZS, and actual improvements of 80% were achieved under optimized machining conditions. The new electrode wires introduced here have excellent characteristics, and are expected to address the needs for improved WEDMworkpiece quality and productivity, automation and reduced work effort. Demand for electrode wires is expected to become increasingly sophisticated and diverse in the future, and Sumitomo Electric will continue to collaborate with EDM manufacturers andusers to develop high-performance WEDM electrode wires.