How to process gaskets using a 400EM medium-speed wire cutting machine?

1.What is medium-speed wire cuttingmachine?

Medium-speed wire cutting machine is a type of wire-cut EDM machine, a precision machining device that falls between fast and slow wire cutting. Wire cutting speeds range from approximately 3-12 m/s (fast wire cutting >12 m/s, slow wire cutting <2 m/s), with machining accuracy reaching ±0.005mm and surface roughness reaching approximately Ra 1.0μm (better than fast wire cutting Ra 2.5μm and slightly inferior to slow wire cutting Ra 0.4μm). Its advantages are higher precision than fast wire cutting and lower cost than slow wire cutting (the equipment price is approximately one-third of that of slow wire cutting, and the machining cost is over 50% lower). This combination of cost-effectiveness and machining accuracy bridges the gap between the insufficient precision of fast wire cutting and the high price of slow wire cutting, making it particularly suitable for small and medium-sized precision parts processing companies, ensuring quality while controlling costs.

2.Working Principle of Medium-speed Wire CuttingMachine

Molybdenum wire (usually 0.12-0.2mm in diameter) is typically used as the electrode. The wire cuts in a bidirectional (reciprocating) motion at a wire speed of approximately 3-12 m/s. A high-frequency pulsed power source generates sparks, which erode the workpiece to achieve cutting.

3.Case Study – 400EM Application Analysis

Recently, Shanghai ANTISHICNC successfully received a mechanical engineer from Australia who wanted to purchase a small wire-cutting machine to produce gaskets with an outer diameter of about 13mm and a required accuracy of ±0.05mm. Following the advice of our Shanghai ANTISHICNC engineers, we matched him with a 400EM CNC medium-speed wire cutting machine with a worktable size of 660*450mm, an X/Y/Z axis travel of 400*320*260mm, a positioning accuracy of ≤0.008mm, a repeat positioning accuracy of ≤0.003mm, and an optimal surface roughness of Ra≤0.8um, which can perfectly meet the customer’s long-term processing needs.

4. Advantages of the 400EM

The 400EM supports internationally recognized G-code and ISO standard codes, and each axis features pitch and backlash compensation, significantly improving machining accuracy. Unlike traditional casting worktables, the 400EM utilizes a corrosion- and rust-resistant steel worktable, effectively extending its service life and enhancing durability. To ensure machining accuracy, the 400EM undergoes comprehensive three-dimensional inspection of machine-machined castings and assembled components using a large-scale three-dimensional coordinate measuring machine from German Zeiss before shipment. Machine motion accuracy is rigorously verified using a British Renishaw laser interferometer, and circular accuracy analysis is performed using a British Renishaw ballbar. These multiple inspection methods ensure high-precision stability when machining various parts.

The technical specifications of the 400EM Medium-speed Wire Cutting Machine are as follows:

5.400EM Gasket Processing

Drawing Analysis

Confirm the machining plan based on the drawing dimensions

Material Selection

Select metal sheets that meet the thickness requirements and check the material flatness

Program Setup

Import the drawing into the machining software to generate the machining program, select the appropriate code format, and set the cutting path

Machine Preparation

Check the molybdenum wire and working fluid; Clamp the workpiece

Main Processing

Start with a higher feed rate to remove most of the excess material, then reduce the feed rate to reduce the discharge current (to avoid burns on the workpiece surface). Gradually correct dimensional errors through two cuts to improve surface roughness.

Precision Inspection

Remove the workpiece, check the surface for residual cutting fluid and debris, and use a micrometer to check the thickness and inner and outer diameters.

If you’re looking for a suitable wire EDM machine, please contact Shanghai ANTISHICNC. We are a seasoned metal machining equipment supplier. Our professional engineers will match you with the most suitable machine based on your needs and provide efficient, customized services.

Keywords: WEDM, wire EDM,Medium-speed wire cutting machine,three-pass wire EDM, gasket-specific wire EDM