(1)High-precision contour cutting and complex internal cavity forming

① Nanometer-level contour tracking and corner control
Utilizing a high-precision servo system and intelligent corner-cutting strategies, the machine achieves precise cutting of complex contours with a contour accuracy of up to ±0.002 mm and a minimum corner radius of R ≤ 0.03 mm. It effectively controls overcutting and lag at corners, meeting the stringent requirements of precision mold inserts and microstructured parts.

② Stable Cutting and Perpendicularity Control for Thick Workpieces
For ultra-thick workpieces (such as large mold inserts) with thicknesses ranging from 100 to 600 mm, the system employs specialized nozzle plates, multi-stage electrical parameters, and taper compensation technology to ensure consistent cutting height throughout the process, with a verticality of ≤0.01 mm per 100 mm and uniform surface striations.

③ Precision Machining of Irregular Bores and Narrow Slots
Capable of machining irregular internal holes such as squares, polygons, and combinations of curves, with a minimum slot width of 0.08 mm and excellent internal corner clearance. Supports direct cutting without perforation (jet drilling), avoiding the damage to the material caused by traditional drilling.

(2)Intelligent Machining Strategies and Surface Integrity Control

①Multi-pass Cutting Process and Precise Control of Surface Roughness
By employing a multi-pass cutting process consisting of rough, intermediate, and finish passes, and by optimizing electrical parameters, wire speed, and flushing pressure, we achieve precise control of surface roughness (Ra) within the range of 0.05–1.6 μm. After finishing, the surface roughness can reach Ra ≤ 0.4 μm, thereby reducing the amount of subsequent polishing required.

② Stress-Free Cutting and Deformation Control Technology
By optimizing cutting paths, employing a stress-relief cutting sequence, and controlling machining allowances, internal stresses in the material are effectively released, preventing deformation in thin-walled and slender parts after cutting and improving dimensional stability by more than 50%.

③ Online Broken Thread Detection and Automatic Threading Recovery
Equipped with a highly sensitive wire break detection system, the machine automatically returns to the break point and rethreads the wire upon a wire break, resuming machining. This significantly reduces the need for manual intervention and minimizes scrap, making it particularly suitable for extended periods of unattended operation.

(3)Capabilities in Special Materials and Microstructure Processing

① Precision Cutting with Cemented Carbide and Metal Ceramics

Capable of cutting complex shapes in cemented carbides and metal ceramics with a hardness of ≥HRA 90, producing cuts free of microcracks and chipping, with dimensional accuracy of ±0.005 mm and excellent surface quality, meeting the requirements for the manufacture of cutting tools and wear-resistant components.

② High-Efficiency, Low-Damage Cutting of Superalloys and Titanium Alloys
For difficult-to-machine materials such as Inconel and Ti6Al4V, the use of specialized electrode wires (galvanized wire, brass wire) combined with high-frequency power supply technology enables high-efficiency cutting (cutting speed ≥ 60 mm²/min) with a heat-affected zone depth of ≤ 0.01 mm.

③ Ultra-precision Cutting of Micro-Electrode Wires
Using ultra-fine electrode wires with diameters ranging from 0.02 to 0.10 mm, in conjunction with ultra-high-precision guides, this process enables the fabrication of microstructures such as microgears, microchannels, and microprobes, with a minimum internal radius of R ≤ 0.015 mm and a contour accuracy of ±0.001 mm.

(4)End-to-end digitalization and automated production

① Intelligent CAD/CAM Programming and Simulation Verification
Supports direct import of formats such as DXF, DWG, and IGES, automatically generates machining paths, and performs collision simulation. It enables automatic nesting for complex parts, optimizes material utilization, and boosts programming efficiency by 70%.

② In-Machine Measurement and Adaptive Machining Compensation
Equipped with a high-precision contact probe, the system automatically aligns the workpiece reference surface, performs online measurement of critical dimensions after cutting, and automatically compensates subsequent cutting paths based on the measurement results, thereby achieving closed-loop machining control.

③ Multi-Machine Networking and Production Management System
Through the DNC network, the system enables centralized program management, automatic task allocation, and real-time monitoring of machining status. Combined with an automatic loading and unloading system (optional), it creates an automated production cell capable of 24-hour continuous operation.