High-precision low speed wire cutting machine threading skills

The EXCELLENCE-20W wire cutting machine is manufactured by Sodick, a renowned Japanese company known for its advanced CNC technology. This machine features a sophisticated wire movement system that allows the electrode wire to move at a controlled speed while maintaining consistent tension (ranging from 2 to 25N). To achieve this, an electromagnetic tension mechanism is integrated into the wire path, using a tension motor and adjusting shaft to apply precise force on the electrode wire. Additionally, the wire removal system includes a micro switch for detecting broken wires, enabling the machine to automatically stop and alert the operator when a break occurs. Although modern high-end wire cutting machines often include automatic threading functions, these systems can be limited in certain scenarios. For example, in machines with longer threading paths or workpieces with thick materials or small threading holes, the automatic threading function may struggle to operate effectively. In such cases, manual threading becomes necessary to restore normal processing capabilities. Mastering manual threading techniques can significantly improve productivity, especially when dealing with frequent wire breaks. Here are some key steps: 1. **Wire Winding**: Begin by winding one end of the electrode wire clockwise around pulley 7, then counterclockwise around the tension control wheel 3. After exiting pulley 7, the wire must pass through the wire breakage monitor and guide 5. It's crucial to ensure the monitor is correctly installed; otherwise, the machine will trigger an alarm: "Wire broken, press the RST key, press the OFF key to stop." Once the wire is threaded through the drum and pulley, adjust the tension to its minimum setting to make it easier to pass through the tension control wheel. Rotate the tension control wheel slightly to help guide the wire smoothly. When the wire reaches the brush position, trim the tip to prevent any obstructions. 2. **Cutting the Electrode Wire Head**: Avoid cutting the wire head flat. Instead, create a slight angle—ideally 30 degrees—to make the tip more tapered, which helps it fit better into the fine guide hole. When threading, do not pull the wire too far out of the guide, as this can cause it to bend or tangle. Instead, slowly feed the wire through the guide. If the wire is too long, it may become difficult to pass through the lower nozzle. To avoid this, try threading while drawing the wire on the side. Use your left hand to rotate the pulley slowly and your right hand to feed the wire gradually until it runs smoothly on its own. Adjust the rotation speed based on the tension you feel—faster when tight, slower when loose. Practicing this technique regularly will improve coordination between both hands and reduce the likelihood of wire bending during threading. 3. **Threading Small Holes**: When working with small threading holes, extra care is needed. The wire should not touch the workpiece while passing through the hole, as this can trigger an alarm: “Machining has stopped due to a short circuit. Press the RST key. Press the OFF key to stop.” To align the wire properly, center it within the hole. If the hole is too small to see clearly, lower the Z-axis and use the AWTW (or T86) code to manually lower the guide tube, creating a tiny water column. Fine-tune this column to hit the exact center of the hole. Once aligned, the wire can pass without triggering an alarm. 4. **Dealing with Clamped Wires**: During processing, if the wire becomes clamped by the pinch wheel, loosen the wheel by pressing the AWT II button (or using the T91 code) and then the OFF button. The screen will display “Off stop, Press the Ack,” so press ACK to resolve the issue. Then proceed with threading using the previously mentioned steps. 5. **General Precautions**: Always ensure the guide wire is pulled down at a moderate speed to prevent the lower nozzle pin from failing to disengage, which could affect the machine’s precision. After completing manual threading, always pull the wire tube back up. Failing to do so may trigger an alarm: “Physical error of AWT, Press the RST key, Press the OFF key to stop.” By following these manual threading techniques, operators can save time and maintain the machine’s performance and accuracy, making it especially useful in teaching, research, and industrial settings.

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