Design on wire cutting process of micro gear based on Opticam

In the extrusion process of micro gear, the micro gear mold has high machining accuracy requirements. The female die is more difficult to machine and the requirement of machining accuracy is more precise than the male die. In this thesis, using a wire cutting plug-in (Opticam) which can attach in NX UG, through the wire cutting process, a micro gear female die with 0.1 mm module and 10 number of teeth is successfully machined by $20\mu\mathrm{m}$ tungsten wire in simulation module. Output the NC files and simulation parameters to actual machining tool, the outside diameter and the root diameter of finished product are both within the error range. Therefore, it is an effective and valid processing technology to use Opticam for wire cutting of micro gear mold.