The possible reasons and solutions of the wire-breaking matters on the low running speed WEDM.

To improve the machining efficiency, we have to solute these matters by finding out the true reasons. There are many reasons that may lead the wire-breakings and possible solutions during the EDM wire cutting.

1) Poor electrical discharging condition: Try to Reduce the P value firstly. If the wire still break, try to reduce I value till wire stops breaking. This parameters adjustment may reduce the machining efficiency. If the wire-breaking happens frequently, please refer to the following information to find out the true reason leading to the wire-broken.

2) Bad coolant flushing condition: For example, the water nozzles are not near to the job surface, or open type cutting. Usually the wire breaking point is in the cutting area, please reduce P value and check if the water nozzle nuts are broken or not, please change them in case nuts are broken.

3) Broken or dirty Power feed contacts: The wire breaking point is near to the power feed contacts if the power feed contacts wears off heavy or too dirty. Please rotate the power feed contacts or change and clean them.

4) Dirty wire guides scuffing the wire. The wire breaking point is near to the wire guides. Please wash and clean the wire guides.

5) Too strong wire tension. Please reduce the wire tension parameter: FW especially during the taper cutting.

6) Un-suitable wire type or/and bad quality work piece material: Change the good quality or bigger diameter wire and reduce P and I value till the wire stops breaking.

7) The electrical short happens for the used wire touches the ground. Usually the wire will break when the machine starts cutting. Try to collect the used wire to the used wire tank to avoid the electrical short.

8）Un-suitable offset value leading to wire-broken during finish cutting. If the offset value is larger, it is hard for the wire to cut it, which may make the wire break. Try to reduce the offset value.

9) The wire breaks near to the back collecting roller. Please check pressing wire ratio on the collecting roller. The standard is 1:1.5.

10) Worse coolant near the power feed contacts. Usually the wire breaks nearby the power feed contacts for the worse coolant condition. Please check the coolant water returning tube.

11) The higher conductivity of the deionized water. The wire usually breaks in the cutting area if the conductivity is 10% higher than standard. Try to lower the conductivity by recycling the water or change the resin.

12) Bad quality deionized water. Usually the wire breaks in the cutting area. After a short time cutting the water is not clear or smells bad. Try to change the filter and water.

13）Broken wire for the pulling. Lower ceramic roller may not rotate smoothly for the used wire inserts the gap. Try to take the used wire off and adjust the ceramic roller again. If necessary, check and change the wire guides.

14) Instability of the wire tensioning roller. Try to adjust the wire tension by tensioning meter.     

Hope above information is helpful to you. For any more information about solutions of the wire EDM machines, please feel free to contact us.

Thanks,

Tech EDM Team

www.techedm.com

sale@techedm.com