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Optimization of cutting route in mold making

ABIS Mold Technology Co.,Ltd Updated: Oct 15, 2018

                      Optimization of cutting route in mold making

   Whether the cutting route is reasonable or not will be related to the deformation of the workpiece.

   Therefore, optimizing the cutting route is beneficial to improve the cutting quality and shorten the processing time.The arrangement of cutting route should be conducive to keeping the workpiece in the same coordinate system with the clamping support during the processing, avoiding the impact of stress and deformation, and following the following principles.

(1) in general, it is better to arrange the starting point of cutting near the clamping end, the cutting section separating the workpiece and its clamping part at the end of the cutting path, and the stopping point near the clamping end of the blank part.

(2) the starting point of the cutting route should be selected in the part with relatively flat surface of the workpiece and little influence on work performance.For the workpiece with high accuracy requirements, it is better to take the starting point of cutting into the precast wire hole on the blank. It is not possible to cut directly from the outside of the blank, so as to avoid deformation at the cutting part.

(3) in order to reduce workpiece deformation, a certain distance should be maintained between the cutting route and the shape of blank, generally no less than 5mm.

   For some specific process requirements, the optimization of the cutting route should be paid attention to.

(1) for some concave model cavities with complex shapes, thick walls or large sections, the secondary cutting method should be adopted to reduce deformation and ensure machining accuracy.Generally, the part with high precision is required to leave a margin of 2mm ~ 3mm for rough cutting first, and after more deformation is released from the workpiece, then fine cutting to the required size.In order to further improve the precision of cutting, before the fine cutting, the remaining 0.20mm ~ 0.30mm is left for semi-fine cutting, which is the three-time cutting method, the first time for rough cutting, the second time for semi-fine cutting and the third time for fine cutting.This is an effective method to improve the precision of die wire cutting.

(2) the Angle cutting method when the workpiece cutting into the "Angle" (or "Angle"), the method can be used, in the original route to add a short cut away, A0, A1 segment is shown in figure 2, the wire electrode cutting point of maximum lag of A0 point program, and then move forward to the additional point A1, and return to nought point, then perform the original program, you can cut out sharp corners.The cutting route of method 2 shown in FIG. 3 can also be adopted, adding a cut of small square or small triangle route at the sharp Angle as an additional program, so as to ensure the cutting edge clear sharp Angle.

(3) during the cutting line discharge machining of the corner, the actual position of the electrode wire is delayed compared with that of the X and Y coordinate axes of the machine due to the reaction force of discharge, resulting in poor corner accuracy.

The lagging movement of the electrode wire will lead to the defect of the workpiece's outer arc machining and the deficiency of inner arc machining, resulting in the decrease of the precision of the workpiece around the corner.For this reason, the driving speed of X and Y axis should be automatically adjusted to slow down the corner where the accuracy of the workpiece is high, so that the actual moving speed of the electrode wire can be synchronized with X and Y axis.That is, the higher the processing precision requirements, the slower the drive speed of the corner.

(4) if the small fillet cutting method finds that the inner fillet radius required by the pattern is less than the offset during cutting, it will cause the phenomenon of "root cutting" at the fillet.For this purpose, it should be made clear that the minimum circular Angle in the contour of the pattern must be larger than the offset of the last cut, otherwise the wire with a finer diameter should be selected.Cutting processing and early repair in the main cutting processing, according to the time when processing different offsets, setting different radius, namely for the section contour of different radius of subroutines, subroutine of the fillet radius should be greater than the time offset of cutting so that it can cut out a small rounded corners, and get the better cutting quality of the rounded corners.

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