I. Wire & Consumables Control (Prevent Breakage at the Source)

1. Cutting Wire Selection & Acceptance

• Use cutting wire with qualified tensile strength, uniform diameter, and stable coating / diamond distribution.
  Reject wire with rust, curling, joints, or surface defects.
• Pre-use inspection: ensure I-wheel deformation-free, burr-free, neatly wound; avoid wire pressing or clamping.
• Set tension limits based on material and wire diameter; no overloading.

2. Guide Rollers, Roller Shafts & Guide System

• Guide rollers: periodic replacement; replace immediately if worn, eccentric, or with abnormal grooves.
  Laser-calibrate parallelism (≤0.02 mm/m) to ensure coplanarity and consistent tangent line.
• Roller shafts: rubber hardness approx. Shore A97, no damage or wire clamping; spindle concentric, no runout.
• Guide blocks / bearings: light contact with wire, no scratching or swinging; positioned 10–15 mm from workpiece to reduce wire bow.

3. Wire Take-up & Pay-off & Arrangement System

• Wire arrangement: closed-loop control with deviation correction algorithm to avoid collapse, stacking, and waviness at both ends.
  Ensure good follow-up performance of take-up and pay-off wheels.
• Tension mechanism: independent or synchronous tension control for multiple wires; calibrate regularly with tension meter to maintain stable no-load / load tension.

II. Equipment & Mechanical Accuracy (Stable Operation Foundation)

• Spindle / Motor: stable rotating speed, balanced torque distribution; reduce speed difference and vibration between wires.
• Frame & Worktable: high rigidity, no resonance; workpiece firmly clamped, no loosening or falling during cutting.
• Cooling / Spraying: full coverage, stable flow, clean filtration; fully cool wire, rollers and cutting zone, flush chips timely to avoid wire jamming and overheating.
• Electrics & Protection: stable voltage (±5%); equipped with emergency stop for sudden tension change, wire speed abnormality detection, and wire breakage stop.

III. Process Parameter Matching (Core for Anti-breakage)

1. Tension Control (Most Critical)

• Set reasonable tension according to wire diameter and material:
  Excessively high tension causes breakage; excessively low tension leads to vibration, slipping and large wire bow.
• Multi-wire system: tension difference within ±5%; closed-loop tension feedback for dynamic stability during cutting.
• Start / stop / reversal: gentle acceleration and deceleration to avoid tension shock.

2. Matching Wire Speed & Feed Rate

• Wire speed: stable without fluctuation, matched with feed rate to avoid excessive wire bow.
• Feed rate: adopt “l(fā)ow first, then high, gradual increment”; excessive feed causes chipping, chip jamming and breakage; overly slow feed reduces efficiency and increases wire consumption.
• For thick / hard materials: reduce feed, enhance cooling, stabilize tension.

IV. Full-Process Management & Control (Long-Term Guarantee)