PCD diamond tool processing for imported slow wire EDM
Contact Info
- Add:棲霞區(qū)峯匯中心7幢1118室, Zip: 210000
- Contact: 陳亞民
- Tel:025-85565899
- Email:sales@nanjingln.com
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FANUC Slow WireFANUC Slow Wireα-C400iC Basic Introduction
Since 1975, when FANUC began producing slow wire electrical discharge machines (FANUC WEDM), decades of continuous technological updates have made FANUC one of the world's leading manufacturers of wire EDM machines. FANUC slow wire EDM machines (FANUC WEDM) are renowned in the industry for their high speed, high precision, high reliability, low-cost maintenance, and intelligence. They are widely used in mold making, medical, and super-hard material manufacturing industries, with high market shares in Japan, Europe, the United States, and Southeast Asia.
FANUC Slow WireFANUC Slow Wireα-C400iC Performance Features
FANUC slow wire (FANUC slow wire) models: α-C400iC, α-C600iC, α-C800iB. All FANUC slow wire machines are originally imported from Japan and come with a 36-month warranty. Equipped with the FANUC system, temperature compensation, fixed core, 3D coordinate rotation, and high-precision automatic wire threading, they achieve high-quality cutting processing.
FANUC Slow WireFANUC Slow Wireα-C400iC Technical Parameters
I. Model, Specifications, Parameters, and Performance of the Equipment
1. Main mechanical parameters of the equipment:
Specification Item | α-C400iC | |||
Processing Method | Immersion Processing / Flush Processing | |||
Maximum Workpiece Size | Without Lifting Door | Standard | 730×630×250mm | |
Option | - | |||
With Lifting Door | Standard | 730×585×250 mm | ||
Option | - | |||
Maximum Workpiece Weight | 500kg | |||
Worktable Surface Size | 626×441mm | |||
Worktable X, Y Travel | 400×300mm | |||
Z-Axis Travel | 255mm | |||
UV-Axis Travel | ±60mm×±60mm | |||
Machine Weight (Including Dry Tank) | Approx. 2200kg | |||
Drive Motor | X/Y Axis | FANUC AC Servo Motor αiF 1/5000-B | ||
U/V Axis | FANUC AC Servo Motor αiF 1/5000-B | |||
Z Axis | FANUC AC Servo Motor αiF 2/5000-B | |||
Maximum Worktable Feed Speed | 2000mm/min | |||
Wire Diameter Used | Φ0.1 ～ Φ0.3mm (Fine Wire Specification Machine: Φ0.05 ～Φ0.3 mm) | |||
Wire Tension | 200 ～ 2500g (Fine Wire Specification Machine: 180 ～2500 g) | |||
Wire Feed Speed | 1 ～15m/min | |||
Minimum Worktable Movement | 0.0001mm | |||
Maximum Taper Angle | Standard | ±30°/ 80mm | ||
Option | ±45°/ 40mm | |||
Wire Guide Nozzle | Die Guide Nozzle | |||
Maximum Wire Weight | Standard | 16kg (Fine Wire Specification Machine: 10kg) | ||
2. Main performance parameters of the equipment:
1) | Maximum Cutting Efficiency: 330mm2/min |
2) | Machine Power Consumption: 13KVA; |
3) | Electrode Wire Diameter: Φ0.10～Φ0.30mm; |
4) | Wire Feed Speed: <15 M/min; |
5) | Best Surface Roughness: Ra≤0.19μm; |
6) | Accuracy (According to JIS Standard): |
X-Axis Positioning Accuracy: ±0.0015mm; X-Axis Repeat Positioning Accuracy: ±0.001mm; Y-Axis Positioning Accuracy: ±0.0015mm; Y-Axis Repeat Positioning Accuracy: ±0.001mm; U, V-Axis Positioning Accuracy: ±0.005mm; U, V-Axis Repeat Positioning Accuracy: ±0.003mm; | |
7) | High-Speed Automatic Wire Threading AWF Function (10-second cycle, automatic threading for 0.10 fine wire) |
8) | Control Unit: FANUC Series 31i-WB |
The calibration of the above accuracy indicators has been completed at the Japanese factory, and the factory accuracy report issued by the Japanese factory shall prevail. | |
Manufacturing Technology
Manufacturing Process
The manufacturing process of PCD tools mainly includes two stages:
①Manufacturing of PCD composite sheets: PCD composite sheets are sintered from natural or synthetic diamond powder and a binder (containing metals such as cobalt and nickel) in a certain proportion under high temperature (1000~2000°C) and high pressure (50,000~100,000 atmospheres). During sintering, the addition of the binder forms bonding bridges mainly composed of TiC, SiC, Fe, Co, Ni, etc., between diamond crystals, and the diamond crystals are embedded in the skeleton of the bonding bridges in a covalent bond form. The composite sheets are usually made into fixed-diameter and thickness disks, and the sintered composite sheets require grinding, polishing, and other corresponding physical and chemical treatments.
②Processing of PCD inserts: The processing of PCD inserts mainly includes cutting the composite sheets, welding the inserts, and grinding the edges.
Cutting Process
Due to the high hardness and wear resistance of PCD composite sheets, special processing techniques must be used. The main processing methods for PCD composite sheets include EDM wire cutting, laser processing, ultrasonic processing, and high-pressure water jet. A comparison of their process characteristics is provided.
Comparison of PCD Composite Sheet Cutting Processes:
Process Method - Process Characteristics
EDM - Highly concentrated pulsed discharge energy and strong discharge force melt the metal in the PCD material, partially graphitizing and oxidizing the diamond, and partially causing diamond脫落 (falling off). Good processability and high efficiency.
Ultrasonic Processing - Low processing efficiency, high consumption of diamond micropowder, and significant dust pollution.
Laser Processing - Non-contact processing, high efficiency, small processing deformation, poor processability.
Among the above processing methods, EDM yields the best results. The presence of bonding bridges in PCD makes EDM processing of composite sheets possible. Under the condition of a working fluid, a pulsed voltage is used to form a discharge channel near the electrode metal in the working fluid, generating discharge sparks locally. The instantaneous high temperature can melt and脫落 (cause to fall off) the polycrystalline diamond, forming the required triangular, rectangular, or square insert blank. The efficiency and surface quality of EDM processing of PCD composite sheets are affected by factors such as cutting speed, PCD grain size, layer thickness, and electrode quality. The rational selection of cutting speed is crucial. Experiments show that increasing the cutting speed reduces the processing surface quality, while too low a cutting speed can cause "wire bowing" and reduce cutting efficiency. Increasing the thickness of the PCD insert also reduces the cutting speed.
| Industry Category | Hardware & Tools/Bearings/Petroleum Machinery Bearing |
|---|---|
| Product Category | |
| Brand: | 發(fā)那科 |
| Spec: | C400iC |
| Stock: | |
| Origin: |
