Reasons For Wire Breakage in Wire Cutting

Reasons for Frequent Wire Breakage in Wire Cutting and Solutions
Wire cutting equipment is widely used in metal processing. However, if the molybdenum wire frequently breaks during production, what could be the reasons, and how should we address them? The following aspects deserve attention:

Poor quality of molybdenum wire: There are numerous brands of molybdenum wire on the market with varying prices. It is essential to choose high-quality molybdenum wire and not just focus on low prices.

1.Unreasonable processing parameters: When processing different materials or workpieces of varying thicknesses, appropriate processing parameters should be selected. If the processing current is set too high, wire breakage is likely to occur.

Worn conductive blocks: Grooves in the conductive blocks can clamp and break the wire. The conductive blocks should be adjusted to a new position. If the wear is severe, they need to be replaced.

2.Inappropriate cutting fluid concentration: The concentration of the cutting fluid should be maintained within the range of 11% to 12.5%. Neither too low nor too high a concentration is suitable for processing.

3.Workpiece deformation clamping the molybdenum wire: Materials may deform due to heat during cutting. It is necessary to select reasonable materials and processing techniques, such as pre-machining wire threading holes, pre-cutting to release stress, and optimizing cutting paths.

Non-conductive impurities inside the workpiece material or non-conductive oxides on the surface: In such cases, the material should be replaced, or non-conductive impurities should be removed before cutting.

4.Insufficient flushing fluid unable to effectively enter the cutting seam: This worsens the discharge conditions and causes wire breakage. A reasonable flushing fluid flow should be set, and regular checks should be conducted to ensure sufficient cutting fluid and unobstructed circulation channels.

Issues with guide wheel accuracy: Bearings should be replaced regularly according to the wire cutting machine maintenance instructions. Guide wheels or bearings should be replaced if necessary.

5.Excessive tension provided by counterweight blocks: The number of counterweight blocks should be selected based on the diameter of the molybdenum wire.

Significant wear of the molybdenum wire: After prolonged use, the molybdenum wire becomes thinner and should be replaced in a timely manner.