A high-efficiency and high-precision single-wire cutting process and system

Abstract

This invention discloses a high-efficiency and high-precision single-wire cutting process and system, comprising the following steps: S1 Initial cutting: Controlling the cutting wire to move in the reciprocating direction, keeping the cutting wire against the outer periphery of the workpiece to cut the workpiece, controlling the workpiece to rotate, the workpiece rotation direction being consistent with the cutting wire movement direction; S2 Mid-section cutting: Controlling the cutting wire to move in the reciprocating direction, simultaneously moving from top to bottom to cut the workpiece, controlling the workpiece to rotate, the workpiece rotation direction being opposite to the cutting wire movement direction; S3 Tail-end cutting: Stopping the workpiece rotation, fixing the workpiece, the cutting wire cutting vertically in a straight line from top to bottom until the workpiece is completely cut off. This invention can improve cutting efficiency and precision.

Description

Technical Field

[0001] This invention relates to the field of cutting equipment technology, and more specifically, to a high-efficiency and high-precision single-wire cutting process, and also to a high-efficiency and high-precision single-wire cutting system. Background Technology

[0002] Single-wire cutting is a machining method that uses a high-speed cutting wire to grind and cut workpieces. It boasts advantages such as high cutting precision and a wide range of applicable materials, and is widely used in metallurgy, machinery manufacturing, and semiconductor industries. When using a single-wire cutting machine to cut large cylindrical workpieces, a rotary cutting method is typically employed. Controlling the workpiece rotation in the opposite direction to the cutting wire increases the relative speed at the cutting position, thereby improving cutting efficiency. Current rotary cutting processes mainly suffer from the following problems:

[0003] When cutting in the initial stage, before the cutting line penetrates the workpiece, the workpiece's rotation can easily cause wobbling, resulting in significant deviations in the initial cut. Moreover, if the entire cutting process involves workpiece rotation, when the cutting reaches a certain depth and the connecting area in the middle of the workpiece is small, a momentary truncation can occur, resulting in a residual boss at the center of the workpiece's cross-section. This requires subsequent grinding, increasing production costs and time. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a high-efficiency and high-precision single-wire cutting process and system that can cut cylindrical workpieces in stages, maintain the accuracy of the initial cutting stage, improve the cutting efficiency of the intermediate stage, maintain the smoothness of the final cutting stage, and maintain the flatness of the cut surface.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A high-efficiency, high-precision single-wire cutting process includes the following steps:

[0007] S1 Initial Cut: Control the cutting line to move in the reciprocating direction, keeping the cutting line in contact with the outer periphery of the workpiece to cut the workpiece; rotate the workpiece, controlling the rotation direction of the workpiece to be consistent with the movement direction of the cutting line.

[0008] S2 Mid-section Cutting: Controls the cutting line to move in the reciprocating direction while simultaneously moving from top to bottom to cut the workpiece; Workpiece rotation is controlled so that the workpiece rotation direction is opposite to the cutting line movement direction.

[0009] S3 Tail Section Cutting: Stop the workpiece rotation, fix the workpiece, and cut a vertical straight line from top to bottom until the workpiece is completely cut off.

[0010] Furthermore, in the initial cutting of step S1, when the cutting line completes a 360° circumferential cut along the outer periphery of the workpiece and the cutting depth reaches the preset value h, the process switches to the middle cutting of step S2.

[0011] Furthermore, the preset value h is 5-30 mm.

[0012] Furthermore, the cutting line cuts from the outer periphery of the workpiece inward, forming a cut portion on the outer periphery of the workpiece and a portion to be cut on the inner periphery of the workpiece. When the outer diameter of the portion to be cut is less than a preset value d, the process switches to step S3 for tail-end cutting.

[0013] Furthermore, the preset value d is 8%-12% of the total diameter of the workpiece.

[0014] Furthermore, in the middle section cutting of step S2, the reciprocating motion of the cutting line includes a forward running phase and a reverse running phase. Between the forward running phase and the reverse running phase, there is a reversal time point t1 where the cutting line has zero speed.

[0015] The process of workpiece rotation control includes a reverse rotation stage and a forward rotation stage. Between the reverse rotation stage and the forward rotation stage, there is a reversal time point t2 where the workpiece speed is zero.

[0016] There is a time difference Δt between time point t2 and time point t1, and the period of the reciprocating motion of the cutting line is T, where 3%T < Δt < 5%T.

[0017] Furthermore, in the mid-section cutting of step S2, the forward running phase is as follows: the cutting line runs in the forward direction, accelerates to a preset linear velocity V2 according to a preset acceleration curve, runs stably at V2, and then decelerates to a stop according to a preset acceleration curve; the reverse running phase is as follows: the cutting line runs in the reverse direction, accelerates to a preset linear velocity -V2 according to a preset acceleration curve, runs stably at -V2, and then decelerates to a stop according to a preset acceleration curve.

[0018] The reverse rotation stage is as follows: the workpiece rotates in the opposite direction, accelerates to the preset speed -V2' according to the preset acceleration curve, runs stably at -V2', and then decelerates to a stop according to the preset acceleration curve;

[0019] The forward rotation stage is as follows: the workpiece rotates in the forward direction, accelerates to the preset speed V2' according to the preset acceleration curve, runs stably at V2', and then decelerates to stop according to the preset acceleration curve.

[0020] Furthermore, in the mid-section cutting of step S2, the process of the cutting line running stably at V2 is synchronized with the process of the workpiece running stably at -V2'; the process of the cutting line running stably at -V2 is synchronized with the process of the workpiece running stably at V2'.

[0021] Furthermore, in the initial cutting step S1, the reciprocating motion of the cutting line is as follows: the cutting line runs in the forward direction, accelerates to a preset linear velocity V1 according to a preset acceleration curve, runs stably at V1 for a set stroke, and then decelerates to a stop according to a preset acceleration curve; the cutting line runs in the reverse direction, accelerates to a preset linear velocity -V1 according to a preset acceleration curve, runs stably at -V1, and then decelerates to a stop according to a preset acceleration curve, and so on in a repeated cycle.

[0022] The workpiece rotation process is as follows: the workpiece rotates in the forward direction, accelerates to the preset speed V1' according to the preset acceleration curve, runs stably at V1', and then decelerates to stop according to the preset acceleration curve; the workpiece rotates in the reverse direction, accelerates to the preset speed -V1' according to the preset acceleration curve, runs stably at -V1', and then decelerates to stop according to the preset acceleration curve, and this cycle repeats.

[0023] In the initial cutting step S1, the reciprocating motion cycle of the cutting line is the same as the rotation cycle of the workpiece; the process of the cutting line running stably at V1 is synchronized with the process of the workpiece running stably at V1'; V1>V1'.

[0024] This invention also provides a high-efficiency, high-precision single-wire cutting system, including a wire cutting assembly, a rotating fixture, and a fixed fixture. The rotating fixture is used to clamp a cylindrical workpiece and can rotate around the axis of the cylindrical workpiece. The wire cutting assembly includes a horizontally arranged cutting wire, which is perpendicular to the axis of the cylindrical workpiece and can be adjusted vertically. The fixed fixture is adapted to the rotating fixture and is used to fix the workpiece in place. Cutting is performed using the high-efficiency, high-precision single-wire cutting process described above.

[0025] In summary, the present invention has the following beneficial effects:

[0026] During the initial cutting process, the direction of the cutting line is controlled to be consistent with the direction of the workpiece, and the workpiece is kept in cyclical control synchronized with the cutting line. This ensures that the cutting line and the workpiece achieve strict synchronous motion control throughout the forward and reverse movement, which can effectively avoid impacts or vibrations caused by inconsistent acceleration changes, and further improve the stability and cutting accuracy of the cutting process. At the end of the cutting process, the workpiece rotation is stopped at the end of the cutting process, the workpiece is supported by a fixture, and the cutting line cuts vertically from top to bottom, finally achieving a flat cut and obtaining a cutting section that meets the requirements.

[0027] In S3 tail-end cutting, the Δt phase time difference design ensures that the zero-position of the cutting line and the workpiece reversal is staggered, and the relative speed never returns to zero throughout the entire process, resulting in continuous and uninterrupted cutting. Combined with an optimal range of 3%T to 5%T, this avoids the zero-speed dead zone of synchronous reversal while preventing unidirectional movement and reduced relative efficiency due to excessively large Δt. Compared to synchronous reversal schemes, the reversal texture depth can be reduced, and the workpiece surface finish is significantly improved. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of a high-efficiency and high-precision single-wire cutting system in this embodiment;

[0029] Figure 2 This is a schematic diagram of the structure for the initial cutting in step S1 of this embodiment;

[0030] Figure 3 This is a schematic diagram of the cutting line and the speed of the workpiece during the initial cutting in step S1 of this embodiment;

[0031] Figure 4 This is a schematic diagram of the segment cutting structure in step S2 of this embodiment;

[0032] Figure 5 This is a schematic diagram of the cutting line and the speed of the workpiece during the segment cutting in step S2 of this embodiment;

[0033] Figure 6 This is a schematic diagram of the cross-section of the cutting line and the workpiece in this embodiment.

[0034] Reference numerals: 1. Wire EDM assembly; 11. Cutting wire; 2. Rotary fixture; 3. Workpiece; 31. Cut part; 32. Part to be cut; 33. Cutting position; 4. Fixture. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] Reference Figures 1-6 As shown, this embodiment discloses a high-efficiency, high-precision single-wire cutting process, including the following steps:

[0037] S1 Initial Cut: The cutting line 11 and the workpiece 3 are cut in the same direction, which can maintain the smoothness of the cut in the initial cutting stage.

[0038] Reference Figure 2 , Figure 3 As shown, in the initial cutting step S1, the cutting line 11 is controlled to move in the reciprocating direction, keeping the cutting line 11 against the outer periphery of the workpiece 3, and cutting the workpiece 3; the workpiece 3 is rotated, and the rotation direction of the workpiece 3 is controlled to be consistent with the movement direction of the cutting line 11.

[0039] In the initial cutting step S1, the reciprocating motion of the cutting line 11 is as follows: the cutting line 11 moves in the forward direction, accelerates to a preset linear velocity V1 according to a preset acceleration curve, runs a set stroke at V1, and then decelerates to a stop according to a preset acceleration curve; the cutting line 11 moves in the reverse direction, accelerates to a preset linear velocity -V1 according to a preset acceleration curve, runs a stable stroke at -V1, and then decelerates to a stop according to a preset acceleration curve, and this cycle repeats.

[0040] The process of workpiece 3 rotating is as follows: workpiece 3 rotates in the forward direction, accelerates to the preset speed V1' according to the preset acceleration curve, runs stably at V1', and then decelerates to stop according to the preset acceleration curve; workpiece 3 rotates in the reverse direction, accelerates to the preset speed -V1' according to the preset acceleration curve, runs stably at -V1', and then decelerates to stop according to the preset acceleration curve, and so on repeatedly; moreover, V1>V1', ensuring the basic material removal capacity.

[0041] During the cutting process, the cutting line 11 moves synchronously with the workpiece 3, ensuring that both can accelerate simultaneously, run in a stable state, and then decelerate simultaneously, maintaining synchronization in each stage.

[0042] The reciprocating motion cycle of the cutting line 11 is the same as the rotation cycle of the workpiece 3.

[0043] The process of the cutting wire 11 running stably at V1 is synchronized with the process of the workpiece 3 running stably at V1'; moreover, during the deceleration process, the cutting wire 11 and the workpiece 3 decelerate to a stop at the same time, that is, they reach the state of zero speed at the same time; then they accelerate in opposite directions in a synchronized manner.

[0044] In the initial cutting step S1, when the cutting line 11 completes a 360° circumferential cut along the outer periphery of the workpiece 3 and the cutting depth reaches the preset value h, the process switches to the intermediate cutting step S2. In this embodiment, the preset value h is 5-30 mm, and h is not less than 2% of the diameter of the workpiece 3.

[0045] S2 Mid-section Cutting: Cutting line 11 and workpiece 3 are cut in opposite directions. During the reverse cutting process, the relative speeds of cutting line 11 and workpiece 3 are superimposed, and the relative cutting efficiency is improved by speed superposition.

[0046] Reference Figure 4 , Figure 5 As shown, in the middle section cutting of step S2, the cutting line 11 is controlled to move in the reciprocating direction, and at the same time moves from top to bottom to cut the workpiece 3; the workpiece 3 rotates, and the rotation direction of the workpiece 3 is controlled to be opposite to the movement direction of the cutting line 11.

[0047] In the mid-segment cutting in step S2, the reciprocating motion of the cutting line 11 includes a forward running phase and a reverse running phase. Between the forward running phase and the reverse running phase, there is a reversal time point t1 where the cutting line 11 has zero speed.

[0048] The process of rotating workpiece 3 includes a reverse rotation stage and a forward rotation stage. Between the reverse rotation stage and the forward rotation stage, there is a reversal time point t2 where the speed of workpiece 3 is zero.

[0049] In this embodiment, time point t2 lags behind time point t1, creating a delay duration Δt between them. Therefore, the zero-speed positions of the cutting line and the workpiece do not directly overlap, avoiding the inefficient cutting state caused by their overlap.

[0050] In this embodiment, there is a time difference Δt between time point t2 and time point t1, and the period of the reciprocating motion of the cutting line 11 is T, where 3%T < Δt < 5%T.

[0051] In the mid-section cutting of step S2, the forward running phase is as follows: the cutting line 11 runs in the forward direction, accelerates to the preset linear velocity V2 according to the preset acceleration curve, runs stably at V2, and then decelerates to stop according to the preset acceleration curve; the reverse running phase is as follows: the cutting line 11 runs in the reverse direction, accelerates to the preset linear velocity -V2 according to the preset acceleration curve, runs stably at -V2, and then decelerates to stop according to the preset acceleration curve.

[0052] The reverse rotation stage is as follows: workpiece 3 rotates in the opposite direction, accelerates to the preset speed -V2' according to the preset acceleration curve, runs stably at -V2', and then decelerates to stop according to the preset acceleration curve;

[0053] The forward rotation stage is as follows: workpiece 3 rotates in the forward direction, accelerates to the preset speed V2' according to the preset acceleration curve, runs stably at V2', and then decelerates to stop according to the preset acceleration curve.

[0054] In the middle section cutting of step S2, the process of the cutting line 11 running stably at V2 is synchronized with the process of the workpiece 3 running stably at -V2'; the process of the cutting line 11 running stably at -V2 is synchronized with the process of the workpiece 3 running stably at V2'.

[0055] Cutting is performed from the outer periphery of the workpiece 3 inward along the cutting line 11. The outer periphery of the workpiece 3 forms the cut portion 31, and the inner periphery of the workpiece 3 forms the portion to be cut 32. When the outer diameter of the portion to be cut 32 is less than the preset value d, the process switches to step S3 for tail section cutting.

[0056] In this embodiment, the preset value d is 8%-12% of the total diameter of workpiece 3.

[0057] S3 Tail-end Cutting: Stop the rotation of workpiece 3, fix workpiece 3, and cut vertically from top to bottom with cutting line 11 until workpiece 3 is completely cut off.

[0058] Reference Figure 6 As shown, when entering step S3 (tail-end cutting), the rotating fixture 2 stops rotating. Furthermore, the workpiece 3 is secured at both ends by the rotating fixture 2 and the fixed fixture 4, maintaining its stability. During the cutting process, the central part 32 of the workpiece 3 is completely severed by the up-and-down moving cutting line, preventing the formation of a broken boss at the center of the cut.

[0059] This embodiment also discloses a high-efficiency and high-precision single-wire cutting system for realizing the above-mentioned high-efficiency and high-precision single-wire cutting process; specifically, the single-wire cutting system in this embodiment includes a wire cutting assembly, a rotating fixture 2, and a fixed fixture 4, as shown in the figure. Figure 1 As shown:

[0060] The rotary fixture 2 can clamp a cylindrical workpiece 3 and drive the workpiece 3 to rotate around its own axis, thereby realizing the rotation action of the workpiece 3.

[0061] The wire EDM assembly 1 includes a cutting wire 11. Both ends of the cutting wire 11 are driven by drive rollers and guided by guide wheels, resulting in a horizontal cutting segment in the middle section of the cutting wire 11. The cutting wire 11 can be driven to reciprocate by various components within the wire EDM assembly. The cutting segment of the cutting wire 11 is perpendicular to the axis of the cylindrical workpiece and its feed can be adjusted vertically.

[0062] In addition, the fixed clamp 4 and the rotating clamp 2 are adapted to clamp both ends of the workpiece, thereby maintaining the stability of the workpiece 3 during rotation. Moreover, during the tail section cutting of S3, the fixed clamp 4 and the rotating clamp 2 can clamp and limit both sides of the workpiece 3, keeping the workpiece 3 in a fixed state, thereby ensuring the accuracy during the tail section cutting process and avoiding the formation of a broken boss at the center of the cut.

[0063] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A high-efficiency, high-precision single-wire cutting process, characterized in that, Includes the following steps: S1 Initial cutting: Control the cutting line (11) to move in the reciprocating direction, keep the cutting line (11) against the outer periphery of the workpiece (3), and cut the workpiece (3); rotate the workpiece (3), and control the rotation direction of the workpiece (3) to be consistent with the movement direction of the cutting line (11); S2 Mid-section cutting: Control the cutting line (11) to move in the reciprocating direction, and at the same time move from top to bottom to cut the workpiece (3); the workpiece (3) rotates, and the rotation direction of the workpiece (3) is controlled to be opposite to the movement direction of the cutting line (11); S3 Tail-end Cutting: Stop the rotation of the workpiece (3), fix the workpiece (3), and cut the cutting line (11) vertically from top to bottom until the workpiece (3) is completely cut off. In the mid-segment cutting in step S2, the reciprocating motion of the cutting line (11) includes a forward running stage and a reverse running stage. Between the forward running stage and the reverse running stage, there is a reversal time point t1 where the cutting line (11) has zero speed. The process of workpiece (3) rotation control includes a reverse rotation stage and a forward rotation stage. Between the reverse rotation stage and the forward rotation stage, there is a reversal time point t2 where the speed of workpiece (3) is zero. There is a time difference Δt between time point t2 and time point t1, and the period of the reciprocating motion of the cutting line (11) is T, 3%T<Δt<5%T; In the middle section cutting in step S2, the forward running stage is as follows: the cutting line (11) runs in the forward direction, accelerates to the preset linear velocity V2 according to the preset acceleration curve, runs stably at V2, and then decelerates to stop according to the preset acceleration curve; the reverse running stage is as follows: the cutting line (11) runs in the reverse direction, accelerates to the preset linear velocity -V2 according to the preset acceleration curve, runs stably at -V2, and then decelerates to stop according to the preset acceleration curve. The reverse rotation stage is as follows: the workpiece (3) rotates in the opposite direction, accelerates to the preset speed -V2' according to the preset acceleration curve, runs stably at -V2', and then decelerates to stop according to the preset acceleration curve; The forward rotation stage is as follows: the workpiece (3) rotates in the forward direction, accelerates to the preset speed V2' according to the preset acceleration curve, runs stably at V2', and then decelerates to stop according to the preset acceleration curve; In the mid-section cutting of step S2, the process of the cutting line (11) running stably at V2 is synchronized with the process of the workpiece (3) running stably at -V2'; the process of the cutting line (11) running stably at -V2 is synchronized with the process of the workpiece (3) running stably at V2'.

2. The high-efficiency, high-precision single-wire cutting process according to claim 1, characterized in that, In the initial cutting of step S1, when the cutting line (11) completes a 360° circumferential cut along the outer periphery of the workpiece (3) and the cutting depth reaches the preset value h, the process switches to the middle cutting of step S2.

3. The high-efficiency, high-precision single-wire cutting process according to claim 2, characterized in that, The preset value h is 5-30mm.

4. The high-efficiency, high-precision single-wire cutting process according to claim 1, characterized in that, In the middle section cutting in step S2, the cutting line (11) cuts from the outer periphery of the workpiece (3) inward. The outer periphery of the workpiece (3) forms the cut part (31), and the inner periphery of the workpiece (3) forms the part to be cut (32). When the outer diameter of the part to be cut (32) is less than the preset value d, the process switches to the tail section cutting in step S3.

5. The high-efficiency, high-precision single-wire cutting process according to claim 4, characterized in that, The preset value d is 8%-12% of the total diameter of the workpiece (3).

6. The high-efficiency, high-precision single-wire cutting process according to claim 1, characterized in that, In the initial cutting step S1, the reciprocating motion of the cutting line (11) is as follows: the cutting line (11) runs in the positive direction, accelerates to the preset linear velocity V1 according to the preset acceleration curve, runs stably at V1 for the set stroke, and then decelerates to stop according to the preset acceleration curve; the cutting line (11) runs in the reverse direction, accelerates to the preset linear velocity -V1 according to the preset acceleration curve, runs stably at -V1, and then decelerates to stop according to the preset acceleration curve, and so on in a cycle. The process of workpiece (3) rotation is as follows: workpiece (3) rotates in the forward direction, accelerates to the preset speed V1' according to the preset acceleration curve, runs stably at V1', and then decelerates to stop according to the preset acceleration curve; workpiece (3) rotates in the reverse direction, accelerates to the preset speed -V1' according to the preset acceleration curve, runs stably at -V1', and then decelerates to stop according to the preset acceleration curve, and so on. In the initial cutting step S1, the reciprocating motion cycle of the cutting line (11) is the same as the rotation cycle of the workpiece (3); the process of the cutting line (11) running stably at V1 is synchronized with the process of the workpiece (3) running stably at V1'; V1>V1'.

7. A high-efficiency, high-precision single-wire cutting system, characterized in that, The device includes a wire cutting assembly (1), a rotating clamp (2), and a fixed clamp (4). The rotating clamp (2) is used to clamp a cylindrical workpiece (3) and can rotate around the axis of the cylindrical workpiece (3). The wire cutting assembly (1) includes a horizontally arranged cutting line (11), which is perpendicular to the axis of the cylindrical workpiece (3) and can be adjusted up and down. The fixed clamp (4) is adapted to the rotating clamp (2) and is used to fix and clamp the workpiece (3). The cutting is performed using the high-efficiency, high-precision single-wire cutting process as described in any one of claims 1-6.

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