Importance of Wire Cutting in Auto Parts Manufacturing

1、Introduction to Wire Cutting

Wire-cut electrical discharge machining (WEDM) is a process that uses a metal wire to generate sparks to remove workpiece material. The wire is usually made of brass or other metals and is fed to the workpiece through a conduit. A high voltage current is then applied to the wire to generate sparks, thereby removing the workpiece material and gradually forming the desired shape. It is a high-precision machining technology that can produce extremely complex shapes, but because it is time-consuming and costly, it is generally only used for special applications. It is widely used in tool and mold manufacturing, military, medical equipment manufacturing and other fields, and is more widely used in automotive parts manufacturing.

2、Benefits of Wire Cutting to the Automotive Industry

1.High Precision
The high precision of wire cutting enables it to produce parts with tight tolerances. It is not only versatile and can process a variety of materials, but also famous for its rapid processing technology, which can produce parts quickly and in large quantities, which is of great significance to the improvement of production efficiency in the automotive industry.

2.No mechanical force required
The wire cutting process does not require any mechanical force when processing precision materials, which is in sharp contrast to other traditional cutting processes that require a lot of force to obtain results, and will not cause deformation or distortion of the final product.

3.Customizable design
Wire cutting EDM can achieve complex designs based on drawings and samples provided by customers. Moreover, the connector mold parts used do not require a lot of mechanical force, making the entire production process more precise. At the same time, it can meet customers’ specific requirements for design, shape and size, and can also process hard and brittle materials in mass production by using the principle of fine wire discharge.

4.Economical and efficient
Automobile production requires the use of durable materials, and the wire cutting process does not apply force during the processing process, and no additional processing is required, thereby reducing costs.

5.Reduce secondary operations
Wire cutting can process parts with extremely fine and smooth surfaces, so no or only very few secondary operations are required.

6.Cutting hard materials
Wire cutting is a widely used processing technology that can be used to cut hard materials. Its technology is not limited by the hardness of the material and is very suitable for processing the hardest materials such as copper, molybdenum, tungsten, etc.

7.Environmental protection
Traditional processing methods will produce a lot of waste after the processing process is completed. The treatment of these wastes is expensive and time-consuming. Wire cutting produces the least waste, which greatly reduces the cost of waste treatment.

3、Automotive Application Examples

1.Bumper
The car bumper is converted from precious metal materials to plastic materials (such as polyester, polyethylene, polycarbonate, etc. and infiltrated with alloy components) and is made by injection molding. In addition to the original protective function, the processed bumper can also be coordinated with the shape, is lighter, and has the advantages of weldability and good coating performance.

2.Instrument panel
The instrument panel is classified in many ways according to safety and comfort. The hard plastic instrument panel adopts injection molding process, which is simple and has low investment; the blister instrument panel presents the surface feeling through a specific process; the semi-hard foam soft instrument panel is filled with polyurethane foam to improve the touch and increase the energy absorption capacity.

3.Car door
The car door provides a channel for people to enter and exit and isolates interference from outside the car. Its quality is reflected in indicators such as anti-collision, sealing, and convenient opening and closing. In order to increase the overall weight of the vehicle, it is made of new plastic materials for injection molding.

4.Air conditioning and filter
The shell of the car air conditioner is an important component. Its structure determines the performance of the air conditioner. It is made of injection molding of new engineering plastic materials. The air conditioner can perform various treatments on the air in the car and has become a symbol of the functional device of the car.

4、Conclusion

In short, wire cutting is of great significance in the manufacturing of automotive parts. Its unique processing principle can bring many benefits to the automotive industry. It is widely used in the manufacturing of various automotive parts and strongly supports the development of automotive parts manufacturing.