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:

Contenido

1. Wheel Cutting Process:

(1) 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.

(1) 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.

(2) 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.

(3) 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.

(4) Post-Treatment:

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

2. Wire Cutting Process:

(1) 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.

(2) 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.

(3) 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.

En resumen

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.

Contacto

LuShan, est. En 1975, es un Chino fabricante profesional que se especializa en los transformadores de potencia y reactores de más de 50 años. Los productos principales son transformador monofásico, trifásico de transformadores de aislamiento, transformador eléctrico, transformador de distribución, el paso hacia abajo y paso transformador de baja tensión del transformador, transformador de alto voltaje, transformador de control, transformador toroidal, R-transformador con núcleo; DC inductores, CA reactores, filtrado de reactor de línea y de carga del reactor, estrangulaciones, el filtrado de los reactores y de los intermedios, de alta frecuencia de los productos.

Nuestros transformadores de potencia y reactores son ampliamente utilizados en las 10 áreas de aplicación: rapid transit, maquinaria de construcción, energía renovable, de fabricación inteligentes, equipos médicos, la mina de carbón de la explosión de la prevención, el sistema de excitación, de vacío, de sinterización(horno), aire acondicionado central.

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