| No. |
Problem |
Location |
Cause |
Checks & Corrective Action |
| 1 |
Wire
Break |
1.
Near the feeder plate |
Feeder Panel is worn |
Check feeder plate & replace if
necessary
Replace during each Preventive Maintenance
rebuild/overhaul |
| Water from the feeder plate nozzle does not hit
the feeder plate |
Clean the feeder plate nozzle and check for
proper water pressure |
| 2.
Near the wire guide |
Wire
guide is dirty |
Check guide and clean; normal
maintenance |
| Wire
is dragging in the guide |
Check for alignment and make
adjustments |
|
Wire guide is not in the proper
location |
Reset the guide accurately |
| 3.
During initial string up |
Wrong wire setting |
Check for proper setting according to
manufacturing practice |
| Wire
tangles or cross overs |
Exchange the spool of wire; untangle the problem
wires, if possible |
| 4.
Immediately after start up and within about
5mm |
Air trapped in processing fluid
Work is not square w/wire |
Processing conditions are not correct. Degrease
the work piece.
Check process fluid water pressure.
Verify the alignment and restart. |
| 5.
After start up & more than about 5 mm |
Low
pressure of process fluid |
Check the process fluid nozzle for position and
wear |
| Inconsistent processing conditions |
Check the suction port of the process fluid tank
for dirt |
| Foreign matter or pinhole inside the work
|
When processing a complicated shape, check ease
of flow/discharge/removal of the fluid |
| Defective wire |
Change the wire |
|
Defective guiding of the wire |
Check the urethane rubber rollers for proper
friction, cuts or dirt
Adjust wire tension to the correct
setting |
| 2 |
Poor accuracy |
1.
Defective shape |
Low wire guide pressure, not maintaining
location |
Adjust the wire guide, reset the wire
guide |
| Low
wire tension |
Set
the wire tension correctly, according to your best
manufacturing practice |
| Large change in ambient temperature |
Remove stress/strain in the work |
| Non-uniform workpiece |
Check vertical alignment of the wire |
| Incorrect offset |
Clean and maintain guide/dies, etc. |
| 3 |
Poor finish or surface
accuracy |
1.
Rough surface |
Inconsistent processing conditions, non-uniform
electrical discharge |
Increase wire feed rate |
| 2.
Longitudinal streaks occur on the processed
surface |
Low
wire tension |
Increase the processing speed |
| Incorrect process parameters |
Increase wire feed rate |
| Slow
processing speeds |
Replace the ion exchange resin & stabilize
the water resistivity |
| Degradation of ion exchange resin |
Clean and maintain the wire guide
system |
| Defective wire guiding |
|
| Low
friction, cuts & dirt on urethane roller |
|
| Incorrect wire tension |
|
| 4 |
Poor processing speed
|
1.
No increase in processing speed |
Inconsistent processing conditions (incorrect
quality of material, plate thickness and size) |
Set
according to conditions in your best manufacturing
practice |
| 5 |
Curling |
1.
Wire not setting & storing easily in the scrap
box |
Non-uniform residual stress in the wire |
Increase applied current by one tap (for
increased processing speed) |
| Partial wear of transfer roller belt |
Replace belts when wear exceeds one third the
diameter of the wire |
| Misalignment of transfer roller belt |
Consult the equipment
manufacturer/dealer |
| Incorrect pressure of transfer roller
belt |
Run
at a belt pressure suitable for the wire |
|
| 6 |
Poor automatic threading because
of poor insertion |
1.
Impossible to thread into guide and workpiece
hole |
The
guide is dirty or clogged up |
Complete cleaning and regular
maintenance |
| Too
small a diameter in the work hole |
Check the machine practices for minimum diameter
of the workpiece hole |
| Misalignment between the upper head and the work
hole |
Manually adjust the water pressure
valve
Check the program and re-center |
|
| Poor automatic threading because
of poor cutting |
Cutting w/cutter
1. Cutting is not performing well |
Partial wear of the cutter and low cutting
power |
Replace the cutter if blades show dents or
wear
Check for proper cutting force and
pressure |
| 2.
Unable to insert into the prepared hole |
Cutting burrs occur at the end of the
wire |
Replace the cutter |
|
| Poor automatic threading because
of poor cutting |
Cutting w/annealer
1. Poor cutting quality |
Incorrect wire diameter data input
|
Adjust cutting to the quality and characteristics
of the wire |
|
2. Cutting location varies |
Poor quality wire
Different quality of wire |
Check data input regarding wire
diameter |