How is the cutting process of the iron core conducted?

Thecore cutting process is crucial in transformer manufacturing, directly affecting the core's performance and quality. To ensure the quality of the core during cutting, various technologies and methods are typically employed. The main cutting techniques include:

Content

●Wheel Cutting Process:

● Wheel Selection: For cutting transformer cores, a thin wheel with a grit size of 50 is commonly used. This type of wheel provides high cutting precision and efficiency, with a rotational speed controlled between 1400 and 3000 revolutions per minute to accommodate differentcore thicknesses and materials.

● Fixing and Protection: During cutting, it is essential to firmly secure the core to prevent deformation, delamination, or flaring at the cutting edges. The cutting speed should be appropriately controlled to minimize wheel wobble athigh speeds, ensuring a smooth and precise cutting surface.

● Cooling and Lubrication: To prevent excessive heat generation during cutting, which can degrade material performance, cooling of the wheel and cutting surface is necessary. The cooling liquid is usually a mixture of rust-inhibiting emulsified oil (also known as soap oil) and water in a 1:5 ratio. Tap water can be used in spring, summer, and autumn, while hot water should be used in winter to dilute theemulsified oil. This approach effectively reduces cutting temperatures and extends wheel life.

● Cooling Liquid Maintenance: To extend the life of the cooling liquid, iron filings can be removed using a magnetic separator, allowing the cooling liquid to be reused. This practice is both economical and environmentally friendly, ensuring effective cooling and cutting quality.

● Post-Treatment: After cutting, the core should be cleaned with gasoline to remove residual cooling liquid and impurities, ensuring cleanliness and smooth subsequent processes.

●Wire Cutting Process:

● Principle and Advantages: Wire cutting machines use a fine metal wire as the electrode and perform cutting through discharge machining. The primary advantages of this method are the smooth cutting surface and minimal stress generated during the process, making it suitable for precision machining of cores with special requirements.

● Process Limitations: Although wire cutting offers high precision and low stress, its cutting speed is relatively slow, limiting its application in mass production. Typically, wire cutting is used forhigh-precision and special-shaped core machining, such as laboratory samples or high-performance transformer cores.

● Cooling and Electrode Maintenance: During wire cutting, cooling liquids are also necessary to lower temperatures and prevent heat from affecting material performance. Maintaining thecleanliness and tension of the electrode wire is crucial for ensuring cutting quality.

In summary

In summary, the choice of core cutting process should be based on specific production needs and technical requirements.Wheel cutting is suitable for large-scale production due to its efficiency and cost-effectiveness, while wire cutting is appropriate forhigh-precision and special-shaped machining, despite its slower speed. Regardless of the method used, ensuring proper core fixation, cooling, and post-treatment is key to maintaining cutting quality and core performance.

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LuShan, est.1975, is a Chinese professional manufacturer specializing in power transformers and reactors for 49 years. Leading products are single phase and three phase isolation transformers, electrical transformer, distribution transformer, step down and step up transformer, low voltage transformer, high voltage transformer, control transformer, toroidal transformer, R-core transformer; DC inductors, AC reactors, line and load reactor, chokes, filtering reactor, and intermediate, high-frequency products. Our power transformers and reactors are widely used in 10 application areas: rapid transit, construction machinery, renewable energy, intelligent manufacturing, medical equipment, coal mine explosion prevention , excitation system, vacuum sintering(furnace), central air conditioning.

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