How to use slow wire cutting to process internal gears?

Recently, a customer from Poland needed to purchase wire cutting for internal gears. The workpiece size was 500*500*200mm, and the required processing accuracy range was 0.01-0.02mm. It needed automatic threading, and it could also automatically rewind after the wire broke. It could work automatically without supervision.

According to the customer’s needs, Antis engineers successfully matched a slow wire-CK650L for the customer. The travel of the X, Y, and Z axes was 400*300*260mm. The maximum workpiece weight was 500kg. The slow wire EDM wire cutting machine is a machine that uses metal wire as an electrode and performs precision cutting by discharging and corroding metal materials. It is especially suitable for processing parts with high hardness, high precision, and complex contours.

CK650L uses a square work surface, standard configuration is not easy to wear quenching work surface, stainless steel processing groove to inhibit the processing fluid or processing chips caused by aging, using the square workpiece support table. Standard 19-inch horizontal operating table, ergonomic design, easy to learn, easy to operate, and the human-machine interface is highly friendly and clear and concise. Standard AWT automatic wire threading function.

The following are the basic parameters of CK-650L:

 ANTISHICNC engineer briefly introduce the process of CK650L processing internal gears:

1.Material preparation and positioning

The workpiece needs to be a conductive material (such as tool steel, stainless steel, tungsten steel, etc.);

The workpiece clamp is mounted on the wire-cut workbench, usually centered.

2.Start hole pre-processing (very critical)

First, drill a small hole (wire hole) in the middle of the workpiece for wire-cutting introduction;

The hole position must be accurately centered, otherwise the tooth profile will be eccentric.

3.Write a simple flow of gears

Use CAD/CAM software (such as: Mastercam, PEPS, or dedicated wire-cut programming software);

Import gear parameters (module, number of teeth, pressure angle, tooth top circle, tooth root circle, etc.) to generate two-dimensional statistics of internal gears;

The software will automatically generate internal gear involute trajectory + multiple cutting paths (rough cutting + fine cutting).

4.Wire-cutting execution

Use 0.1~0.25mm fine wire, select according to accuracy. Usually multiple cutting (rough cutting 1 time + fine cutting 2~3 times) is used to achieve the above-mentioned tooth profile accuracy and surface quality.

5.Fine finishing and inspection

The tooth profile deviation (involute clearance, pitch clearance, etc.) can be detected using a three-coordinate or gear measuring instrument;

If the gear is a functional part (such as matching with a shaft), the inner hole concentricity and tolerance need to be detected.

If you have any questions, please contact Shanghai ANTS Machiner Equipment Co., Ltd. through our website information. Engineers will match you with efficient machine tools and professional services.

Keywords: precision machining, slow wire cutting, slow wire cutting internal gear