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1 First, according to the size of the workpiece to be processed, the thin copper sheet (thickness is determined according to the condition of the wire electrode and the shape of the processing site) is cut into strips, and then folded, and the length of the folded portion is guaranteed to be long and short. The purpose of using a short copper sheet is to reduce the thickness of the copper sheet, so that the upper nozzle is closer to the workpiece processing site, in order to improve the processing accuracy;

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2 Then the folded part of the folded copper sheet is hammered with a small hammer and repaired with the assorted files to the shape shown in Fig. 3;

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3 Then put the above processed copper sheet into the gap formed by wire electrode processing, and at the same time, drip 502 glue on the surface of the part of the workpiece (ie epoxy resin instantaneously quick-drying glue). Due to cutting, the high pressure flushing of the electric discharge wire cutter makes the workpiece subjected to high pressure. If pure copper is used to ensure the conductivity and fixation, the following problems will be easily caused: (a) The copper piece is too loose to be fixed. Unreliable, conductive and unstable; (b) copper plate too tight, but also worried about the damage to the surface of the workpiece, damage shape tolerances, so the use of 502 glue to ensure that the cut part is fixed with the parent material;

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4 When inserting the copper piece into the processing area, the BC section should be stuffed into the gap according to Figure 4, and the AD section should be leveled so that the upper nozzle is closer to the workpiece to ensure the machining accuracy. After the processing is complete, straighten the copper piece out of the gap. In particular, attention should be paid to the following: When connecting the copper piece with 502 glue, keep it away from the remaining part of the workpiece to prevent the 502 glue from penetrating into the threading hole of the godet just below it, causing plugging of the threading hole. In addition, the position of the adhesive copper sheet should be symmetrically distributed, and it should be ensured that the plug is tight at the same time to prevent the workpiece from shifting, which will affect the quality of the workpiece.

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2. Fill the conductive copper sheet between the cut portion and the parent material. The thin copper sheets folded, cut, hammered, and repaired are filled into the gap formed by the in-line electrode processing, and the copper sheet and the gap wall are closely fitted. The purpose of filling this copper sheet is to conduct electricity because the 502 glue is used when pasting the copper sheet, and the 502 glue is not conductive. In order to realize the conductive requirement, the method of filling the conductive copper sheet is adopted. When filling the conductive copper sheet, attention should also be paid to the symmetrical arrangement of the copper sheet and the copper sheet should be tightened at the same time, and the plug cannot be too tight so as not to scratch the surface of the workpiece.

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According to the author's experience, whether it is to paste the connection copper or fill the conductive copper gap shape. For example, taking Figure 5 as an example, small copper pieces should be made into circular arcs, and the surface of the hammered copper pieces should be polished with a metallographic emery cloth to ensure that the copper surface is smooth to avoid scratching the workpiece. surface.

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Note: In the multiple cutting of the residual part of the wire-cut workpiece, the conductive problem of the workpiece to be processed must be solved first, because in the high-precision wire cutting process, the travel route of the wire electrode may need to travel multiple times along the processing path to To ensure that the workpiece has a high surface roughness and surface accuracy, then wire cutting processing is to rely on the remaining part of the workpiece to play a conductive role in the normal electrical processing to ensure. However, when cutting the remaining part of the workpiece, cutting the remaining part of the workpiece for the first time will cause the part to be cut to be separated from the mother, so that the conductive circuit will be interrupted and the continuous processing will not be possible. In consideration of the circumstance and continuation, it is necessary to maintain the normal conduction between the remaining part of the workpiece and the mother even in the case of multiple cutting.