Taizhou Tongfang CNC Machine Tool Co., Ltd.

DK77 Series EDM Wire Cutting

Machine

Manual

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 Taizhou Tongfang CNC Machine Tool Co., Ltd.

Part 1 Electric
First. Safety protection of machine tool electrical
1. The machine tool electrical uses a three-phase four-wire AC power supply with a
voltage range of 380V±10%, higher than this voltage, the electronic components will
be burned at your own risk.
2.The machine tool is equipped with protective grounding electrical appliances. The
user should pay attention to the machine tool to be reliably grounded to meet the
Continuity requirements for protective grounding ensure the personal safety of
operators.
3.There is a red emergency stop button on the electrical operation panel of the
machine tool. The red emergency stop button can quickly cut off the power of
electrical equipment, and the machine tool stops immediately.
4.Over current protection:
A fuse is connected to the three-phase power supply line of the machine tool and the
lighting circuit for overcurrent protection. The rated current value of its fuse is strict,
and the user must not increase or decrease at will, so as not to prevent protection.
5. Energy consumption braking. Under any of the following conditions, the wire drum
motor can quickly brake within 1～2S:
(1) During a power outage;
(2) When the molybdenum wire is disconnected;
(3) At the end of processing;
(4) When the wire feeder exceeds the set stroke.
Second. The machine operation panel
1. SB1—emergency stop button: When an emergency occurs, press this button to cut
off the power supply of the machine.
2. SB2—Power start button of the whole machine.
3. HL—Power indicator.
4. SB4, SB5—Stop motor start and stop button.
5. SB6, SB7—pump motor stop button.
6. SB3—Broken wire protection knob.
7. SB8—Processing end knob.

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Third. The operating procedures
1. Connect the three-phase four-wire power supply of the machine tool peripherals,
close the power switch, and the HL power indicator on the operation panel lights up.
2. Turn knob SB3 to the "0" position.
3. Press the button SB2, and the machine tool enters the ready state.
4. Press the SB5 wire transport motor M1 to run in the forward direction.
5, press the button SB7 pump motor M2 should run forward.
6.Turn the knobs SB3 and SB8 to the "1" position. (Note: At this time, the console
must be connected and the molybdenum wire is correctly installed. When the
molybdenum wire is not installed and the console is not connected, the knob SB3
must be connected. SB8 can be turned to the "0" position to start the machine.) After
the wire is broken or processing is finished, the machine will stop automatically.
Fourth. The electrical control principle of machine tools
The electrical circuit of this machine tool uses thyristor to control the commutation,
and has the characteristics of low noise and so on.
It has functions such as broken wire protection, over-travel protection, emergency
braking, and stopping after processing.
1. Turn on the peripheral power switch of the machine tool, and the power indicator
HL is on.
2. The control transformer TC is powered on, and the machine tool light switch is
turned on, and the light lamp EL is turned on.
3. Connect the console, install the molybdenum wire, and press the SB2 contactor
KM1 to energize and pull in.
4. Press the button SB7, the contactor KM3 is energized and sucked, and the pump
motor M2 runs to send the saponified liquid to the working point. Press the button
SB6, the contactor KM3 is released, and the pump motor M2 stops running.
5.Press the button SB5, the contactor KM2 is energized and attracted.
(1) The wire transport motor M1 runs, and the wire transport carriage and
molybdenum wire are running in the forward direction.
(2) The 220V voltage between the phase power source V2 and the neutral N is
rectified by the resistor R1 and the diode D1 to charge the capacitor C1, which is
prepared for the motor M1 energy consumption control action.
(3) When the impact block on the wire carriage is pressed to the travel switch Q1-3,
KA1 is energized and combined with the self-locking control commutation circuit to
make the wire transportation motor M1 run in reverse, and the wire carriage and
molybdenum wire move in reverse.
(4) When the impact block on the wire transport carriage is pressed to the travel
switch SQl-2 in the other direction, KA1 is released from power loss, and the
commutation circuit is controlled to make the wire transport motor M1 move forward
to complete a cycle.
(5) SQ1-2 or SQ-3 is turned off during the period when the bumper is pressed on the
travel switch, and KA2 is released after power failure to cut off the high-frequency
output.
(6) Gently press the button SB4 contactor KM2 to release power. The wire transport

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motor M1 inertially moves until it stops. Press the button SB4 hard and the wire
transport motor M1 immediately stops braking.
(7) Press the emergency stop button SB1, the machine tool is powered off, and the
electric energy stored in the capacitor C1 is released in the coil of the wire transport
motor M1, and the energy-consumption braking of the wire transport motor M1 is
realized, and the wire transport barrel immediately stops moving.
Fifth. Machine tool and console connection and pump / power wiring definition

1.Definition of XS4 power inlet four-core plug socket:

1 pin -N, connected to the zero line. Pins 2, 3, and 4 of L1, L2, and L3 are
respectively connected to three-phase power.
2. Definition of XS6 water pump four-pin plug socket: 1 pin-PE, ground wire. 2, 3, 4
feet U3, V3, W3, respectively connected to the pump.
3.The definition of the 30-pin socket connected between the XS5 machine tool and
the console is shown in the table below.
Pin No. No. Description
1 2L+ Motor power
2 2L+ Motor power
3 U1 U-axis motor
4 U2 U-axis motor
5 U3 U-axis motor
6 V1 V-axis motor
7 V2 V-axis motor
8 V3 V-axis motor
9 X1 X-axis motor
10 X2 X-axis motor
11 X3 X-axis motor
12 X4 X-axis motor
13 X5 X-axis motor
14 Y1 Y-axis motor
15 Y2 Y-axis motor
16 Y3 Y-axis motor
17 Y4 Y-axis motor
18 Y5 Y-axis motor

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19 1L+ Motor power
20 1L+ Motor power
21 21 Stop switch
22 23 Stop switch
23 30 High frequency switch
24 32 High frequency switch
25 P+ Sampling+
26 P- Sampling-
27 G+ Workpiece
28 G+ Workpiece
29 G- Molybdenum wire
30 G- Molybdenum wire
Sixth. Electrical schematic diagram:

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Part 2 Machinery
First. Use
DK series CNC EDM machine is composed of CNC machine, high frequency power
supply and machine tool host. This product is suitable for processing various high
precision, high hardness, high toughness metal stamping dies, templates, and parts
with complex shapes in industrial sectors such as electronic instruments and meters,
household appliances, precision quilts, light industry, and military industry. It is a
necessary machine tool in the composition of machining.
Second. The main specifications of the machine tool and related parameters

Third. The machine tool overview

EDM technology has been widely used, and it also shows one of the processing
methods that are difficult to achieve by other machine tools.
The basic principle of wire electric discharge machining is to use a tool electrode to
perform pulse discharge on the workpiece to achieve processing. Wire electric
discharge machining does not need to make a formed electrode, and uses a thin metal
wire (usually called an electrode wire) as the tool electrode. The positive electrode of
the pulse power supply is connected to the workpiece, and the negative electrode is
connected to the electrode wire; the electrode wire moves back and forth at a certain
speed, and it continuously enters and leaves the discharge area; at the same time, a
liquid medium is sprayed between the electrode wire and the workpiece. As long as
the operator effectively controls the speed and trajectory of the electrode wire relative
to the workpiece, the workpiece can be cut to the required shape and size. The
trajectory of the workpiece movement is formed by the coordinate table (two
controlled stepping motors in the vertical and horizontal directions) in X and Y
directions.
The mainframe of Dk series CNC wire cutting machine tool is composed of bed, table,

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wire transport device, wire rack, coolant tank, machine tool electrical appliances,
accessories and other components. It uses the bed as the base, and the workbench,
wire transport device and wire rack are installed on the same base surface of the bed.

The following are introduced separately:

1. Bed
The bed is a box-shaped cast iron, and the upper part is installed with a table, a wire
storage tube, a wire rack, a lighting lamp and other components.
2.Workbench
The worktable is mainly composed of a worktable surface, a middle carriage, a ball
screw, and a variable speed gear box. Ball screw has the advantages of high
transmission accuracy, high efficiency and long life.

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3.Wire transport device
The wire storage cylinder is composed of a thin-walled hollow cylinder. The motor
drives the wire storage drum to rotate through the joint, and at the same time, the
reciprocating movement of the wire winding drum comes from the screw after the
gear is shifted to drive the carriage of the wire transport device. The wire transport
carriage adopts a V-shaped track ball structure, and the oil tank is filled with oil so
that the carriage always slides on the oil surface to extend the service life of the wire
transport.
The frequent reversing of the wire storage tray is controlled by a set of travel switches.
The structure is simple and sensitive. Overload safety devices are provided on the left
and right bumpers. When the travel switch reversal fails, the current of the wire
transport motor is cut off.
4.Wire rack
Molybdenum wire resembles a closed conveyor belt. It is driven by a reel to work
back and forth. A row of wire wheels and a pair of main wheels are wrapped around
the molybdenum wire and follow.
The wire frame part is composed of upright posts and upper and lower wire racks.
Loosen the upper wire frame fixing screws and rotate the column screw with a rocker
to enable the upper wire frame to change the span of the wire frame according to the
requirements of the processed parts. In addition, loosen the fixing screws of the lower
thread stand, and adjust the back and forth 6mm, which can make the molybdenum
wire move forward and backward, and it is convenient to adjust the molybdenum wire
vertical.
5.Coolant tank
The pump sends the working fluid to the processing area, and the sediment
accumulates in the dirt box, which must be cleaned regularly. DX-1 saponification
liquid is used as the working coolant.
6.Accessories
(1) Fixtures: Groups of fixtures are used to fix flat or cylindrical workpieces, and they
are connected to the pressure plate screw structure. Fix the fixtures to the work table
with T-type screws.
(2) rocker: used to rotate the wire storage drum when the wire is wound, the span
adjustment of the wire frame, etc.
(3) Tightening wire wheel: used to manually tension molybdenum wire.
Fourth. Machine tool lubrication system
Every machine's moving parts are lubricated by manual regular lubrication.
Note: The high-speed grease for the rolling bearings of the guide rollers on the wire
frame is replaced every two weeks.

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Fifth. Machine tool operating system

Sixth. Cooling system

During the cutting process, the molybdenum wire and the workpiece require sufficient
coolant. The coolant tank is an output device that supplies the coolant with pressure to
the work area. The cooling liquid is guided by the upper and lower nozzles, and is
brought into the gap of the cutting process with the movement of the molybdenum
wire, thereby the particles and debris on the cutting surface are discharged out of the
gap, and the molybdenum wire is cooled.
There are two knobs on the wire frame body, which are the adjustment switches of the
upper and lower nozzles, respectively, for adjusting the flow of the upper and lower
nozzles.
Seventh. Lifting and installation of machine tools
1. When the machine tool is being transported, try to avoid impact and intense
vibration. Hanging holes have been installed on the upper corners of the bed for
hanging
In use, the length and lifting angle of the wire rope to be lifted should be appropriate.
Avoid contact between the rope and the parts of the machine tool. If necessary, put
soft materials in the contact area to avoid scratching the appearance and damaging the
paint and the accuracy of the whole machine.
2. Machine tool installation
The CNC wire cutting machine is a precision machine tool, so no strong vibration
source, strong electromagnetic flux field and noise interference are allowed around its
work site, otherwise it will directly affect its normal work. The foundation is isolated
from the earthquake source, and the shock-proof trench can be filled with soft
materials to dampen the shock. The texture of the concrete foundation requires casting.

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The basic surface should be able to reasonably place the machine tool host,
high-frequency power supply and CNC machine.
The machine tool should be installed in a natural horizontal position on the foundation,
and the level adjuster under the bed can be used. The installation direction of the
machine tool should make the operator face the natural light source as much as
possible.
3. Conditions of use for machine tools
(1) This machine tool is a precision machine tool. The work area should be kept tidy
and isolated from external vibration sources, and try to avoid strong electromagnetic
fields nearby.
(2) The working environment temperature is 20 ℃ ± 5 ℃, and the relative humidity is
not more than 80%.
(3) When the external power supply voltage fluctuates greatly, the CNC power supply
must be connected to a dedicated regulated power supply.
Eighth. Operation and adjustment of machine tools
1. Preparations before working
(1) Start the power switch, let the machine tool run without load, and observe whether
its working status is normal.
● The control machine must work normally for more than ten minutes;
● The movement of each part of the machine tool should work normally;
● Pulse power supply and machine tool electrical work normally without errors;
● Each travel switch contact is sensitive;
● Each working fluid enters and exits from the pipeline, the valve is unobstructed, the
pressure is normal, and the lift meets the requirements.
(2) Add or replace working fluid
Generally, it is advisable to replace it every other week.
(3) Decide whether to replace the electrode wire
3.Check the workbench
Press the key of the control machine keyboard to control the stepping motor, and
shake the workbench horizontally and vertically to check whether the stepping motor
is sucked. Enter a certain amount of displacement to make the scale rotate forward
and reverse each time, and check whether the scale returns to the "0" position.
4. Work clamping
(1) Fix the fixture on the workbench.
(2) When clamping the workpiece, the reference plane of the workpiece should be
aligned with a dial indicator according to the requirements of the drawing, so that it is
parallel to the horizontal or vertical direction of the workbench.
(3) Check if the workpiece position is within the valid range of the table stroke.
(4) During the cutting process, the workpiece and fixture should not touch any part of
the wire frame.
(5) After the workpiece is completely clamped, all debris on the work surface must be
cleaned.
5.Adjustment of guide wheel
When adjusting the guide wheels, it is necessary to keep the guide wheels rotating

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flexibly without axial movement. When replacing the guide wheel, add high-speed
grease to the bearing.
6.Operation steps
(1) Power on
Press the power switch to turn on the power.
(2) Enter the processing program into the controller
(3) Fortune wire
Press the wire transport switch to allow the electrode wire to run empty, and check the
jitter and tightness of the electrode wire. If the electrode wire is too loose, then
The wire should be tight and tight evenly.
(4) Turn on the water pump and adjust the water spray volume
When turning on the water pump, please first adjust the regulating valve to the closed
state, and then gradually open it, and adjust it to the upper and lower water jets to
contain the electrode wire. The water jet can be directed to the cutting area, and the
amount of water need not be too large. There is a drainage hole in the front of the
bottom of the upper frame, which is often kept clear to prevent water accumulated in
the upper frame from penetrating into the electrical box of the machine tool.
(5) Select the electrical parameters for the on-pulse power supply
The user should select the most suitable electrical parameters according to the
requirements for cutting efficiency, accuracy and surface roughness. When the
electrode wire is cut into the workpiece, please pull the pulse interval apart. After
cutting, adjust the pulse interval when it is stable to make the processing current meet
the requirements.
(6) Turn on the controller and enter the processing state. Observe whether the pointer
is stable during the cutting process of the ammeter, carefully adjust it, and avoid short
circuit.
(7) After processing, the water pump motor should be turned off first, then the wire
transport motor should be turned off, and check whether the X and Y coordinates
reach the end point. When the end point is reached, remove the workpiece, clean and
check the quality; if it does not reach the end point, check whether the program is
wrong or the control machine is faulty, and take timely remedial measures to prevent
the workpiece from being scrapped.
There are red emergency stop button switches on the electrical control panel and
control panel of the machine tool. If there is an unexpected situation during work,
press this switch to shut off the power.
Ninth. Machine tool maintenance
Correct and reasonable adjustment and use and attention to the maintenance of the
machine tool can ensure the cutting accuracy of the machine tool and prolong the use
of the machine tool.
With regard to life, the following requirements are put forward:
1. The whole machine should always be kept clean. The workbench, fixtures, wire
transport parts and their untreated metal are exposed. If they are not used for more
than 8 hours, they should be wiped clean and oiled to prevent rust.
2. In the case of normal use of the machine tool, the transmission parts must be

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lubricated according to the previous requirements.
3.The main wheel of the wire frame components and the cleaning work around the
wire-discharging wheel are particularly important. It should be cleaned frequently
with kerosene. After cleaning, the dirty oil must not leak into the backwater tank of
the workbench, so as to avoid the influence of the coolant flowing in the coolant tank.
Performance of working fluid.
4. The guide wheel and its shaft follow. Due to the poor working conditions and short
service life, it depends on the use situation. Generally, it can be replaced as a set in
2-3 months.
5. Under normal use of the machine, the coolant is changed once a week.
6. When the machine is working, the operator must not leave the site. When a wire
break occurs (the machine has a wire break protection device), the broken wire should
be cleaned up to avoid damage to the wire transport device.
7. In order to be able to master the performance of this machine tool as quickly as
possible and to make the machine tool play its maximum effectiveness, clear and
fixed operation and maintenance personnel are required.
Tenth. Faults and troubleshooting

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Eleventh. Processing technology characteristics of machine tools

In order to make better use of the efficiency of wire cutting machine tools, please pay
attention to the following points when using the machine:
1. Calculate the coordinate point preparation program according to the size of the
drawing and the actual situation of the workpiece, but consider the clamping method
of the workpiece and the diameter of the electrode wire, and choose a reasonable
cutting position.
2.According to the prepared program, use a punching machine to empty the paper
tape, and proofread the punched paper tape. For workpieces with complex shapes, it is
best to operate the control machine to make the machine run away once, or cut the
sheet test piece to check the road by step. Prepared procedures.
3. Pay attention to the position and the moving range of the worktable when clamping
the workpiece, so that the processing cavity conforms to the requirements of the
drawing. For workpieces with small machining allowances or special requirements, it
is necessary to precisely adjust the parallelism of the workpiece with the longitudinal
and horizontal movement direction of the worktable to avoid scrapping the workpiece
when the allowance is not enough, and record the starting vertical and horizontal
coordinate values ​ ​ of the worktable.
4. When processing the die, the discharge plate, the fixed plate and some special
cavities, it is necessary to first penetrate the electrode wire into the pre-drilling hole of
the workpiece.
5. Must be familiar with some particularities in the wire cutting process, the main
factors affecting the accuracy of EDM cutting and specific instructions to improve the
processing accuracy, and give full play to the economic benefits of machine tools. In
the online cutting process, in addition to the accuracy of the machine tool directly
affecting the machining accuracy, the change in the spark gap between the electrode
wire and the workpiece and the deformation of the workpiece also have a negligible

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effect on the machining accuracy.
6. Machine tool accuracy
The accuracy of the machine tool has been fully tested and qualified according to
relevant standards before leaving the factory, but the operator must still perform the
necessary precision inspection and adjustment of the machine tool between machining
precision workpieces.
(1) Check the guide wheel: Before machining, the V-groove of the guide wheel should
be carefully checked for damage, and the electro-corrosives accumulated in the
V-groove should be removed.
(2) Check the clearance of the horizontal and vertical screw pairs of the workbench.
Because frequent reciprocating movements will change the transmission accuracy,
before machining precision workpieces, you must carefully check and adjust to meet
the corresponding standards before you start machining.
(3) The spark gap and size between the electrode wire and the workpiece are closely
related to various factors such as material, cutting speed, and coolant composition.
● The change of spark gap varies with the workpiece material, heat treatment and
cutting thickness. It is due to the differences in the chemical, physical, and mechanical
properties of the material, and the chip removal and ionization capacity during
cutting.
● Relationship between spark gap size and cutting speed
In the effective processing range, the cutting speed is fast, the spark gap is small, the
cutting speed is slow, and the spark gap is large, but the cutting speed must not exceed
the corrosion speed, otherwise a short circuit will occur. Maintain a certain processing
current during the cutting process, then the voltage between the workpiece and the
electrode wire will be constant, and the size of the spark gap will be constant.
Therefore, to improve the processing accuracy, try to achieve a uniform frequency
conversion during the cutting process, and the processing current will Basically stable,
the cutting speed can be maintained at a uniform speed.
● Relationship between spark gap size and coolant
Different coolant components have different resistivity, different chip removal and
ionization capacity, which affect the size of spark gap. Therefore, when machining
high-precision workpieces, be sure to measure the spark gap and program or select the
gap compensation amount.
7. Measures to reduce deformation of workpiece materials
(1) Reasonable process route
When wire cutting is the main process, the processing route of steel parts: blanking,
forging, annealing, mechanical finishing, quenching and tempering, grinding, wire
cutting, and fitter repair.
(2) Selection of workpiece materials
The material of the workpiece should be selected with a small amount of deformation,
good hardenability, and high yield limit. If used as a concave and convex mold
material, Cr-WMn, Cr12Mo, GCrl5 and other alloy tool steel should be selected as
much as possible.
(3) Improve the quality of forging blanks

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Forging should be carried out strictly according to the specifications, and the
temperature of initial forging and final forging should be mastered. Especially for
high alloy tool steels, the degree of carbide segregation should be paid attention to.
After forging, spheroidizing annealing should be performed to refine the grains and
minimize heat treatment Residual stress.
(4) Pay attention to the quality of heat treatment
During heat treatment quenching and tempering, process parameters should be
reasonably selected, strictly controlled specifications, and operations must be correct.
The lower limit of the quenching heating temperature should be used as far as
possible, and the cooling should be uniform, and the tempering should be timely.
Eliminates residual stress after heat treatment.
(5) Reasonable process measures
● Arrange the sequence of hot and cold processes correctly to eliminate the stress
caused by machining.
● When cutting the punch from the blank, you cannot cut it from the outside. Make a
threading hole closer to the contour of the punch. At the same time, pay attention that
the cutting position must not be too close to the periphery of the blank. Make sure that
the blank is adequate. Strength, otherwise it will cause deformation of the cutting
workpiece.
● The starting point of the cutting is best at the balance of the main amount of the
figure, and at the junction of the two sections of the contour, so that the opening
deformation is small.
● When cutting large workpieces, add a splint while cutting, or pad them to reduce the
deformation caused by the processed part hanging down.
● For small or slender workpieces, the factors affecting the deformation are
complicated. The cutting method is used for cutting, measuring while cutting, and
correcting the program until the requirements of the drawing are reached.
Twelfth. Details of rolling bearings

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Machine tool maintenance and repair and troubleshooting

The machine tool can be adjusted, used and maintained correctly and reasonably,
which can not only ensure the accuracy of the machine tool, but also prolong the
service life of the machine tool. Therefore, the machine requires the following:
1. Regular maintenance
When the machine tool has worked for more than 5000 hours (three years), it should
be overhauled once.
2. Daily maintenance
2.1 The machine tool should be kept clean, and the splashed working fluid should be
wiped off in a timely manner. After the machine is stopped, the corrosion on the work
surface should be cleaned up, especially the guide wheel and the conductive block,
which should be cleaned frequently with kerosene to maintain good work status.
2.2 Anti-rust: When the machine is stopped for more than 8 hours, in addition to the
machine tool should be cleaned, parts of the processing area should be oiled to
protect.
2.3 Machine tool lubrication: read machine tool lubrication table

2.4 Guide wheel

Before processing, you should carefully check the introduction and the wear condition
of the "V" groove of the wire roller. If there is serious wear, you should replace it in
time. The quality of the guide wheel has a great impact on the machining accuracy.
You must choose a high-quality guide wheel and install the guide wheel. At this time,
the precision rail bearing should be gently statically pressed in the bearing housing of
the guide wheel. It cannot be disassembled and reassembled, and the assembly
accuracy is broken.
2.5 Working fluid
This machine tool generally uses DX-1 type saponification liquid, working fluid made
according to a 10% concentration ratio, and is generally replaced once every 10 days
or the processing effect will be affected.
2.6 Broken wire treatment
During processing, if a broken wire occurs, it should be stopped in time to clear the
broken wire and replace it with a new wire. Do not allow broken wires to run for a

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long time to avoid accidents.
2.7 Conductive block
Always check whether the conductive block has good and reliable contact with the
molybdenum wire. If the contact is not good, it will directly affect the work stability
and processing efficiency. If the conductive block is worn, it should be replaced in
time.

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