Wire electrical discharge machining (wire EDM) is a process that works by continuously feeding a wire electrode under tension on a vertical axis. Discharge voltage is applied through the wire, crosses via a dielectric liquid, and strikes the grounded workpiece. The workpiece is moved in an X-Y plane to trace a cut pattern through the material. This erosion can commence from the outside edges of the workpiece or by drilling a hole first. EDM is capable of eroding a hole through the billet to be used as a starting point for a contained cut path.
Wire EDM is used for the direct, single-stage processing of hard materials from basic billet form to a finished state. Its single-stage nature reduces costs and improves toolmaking precision for a range of industries, including: extruder, punch, and die tooling, aerospace, medical equipment, automotive, and electronics.
Wire EDM Process
During the wire EDM process, a metal part is put into dielectric fluid, and a wire The wire is passed through the submerged metal part. Electricity is sent through the part to create a spark that ultimately helps create the desired part shape.
When the distance between the electrodes is narrowed, the electric field strength increases, thereby increasing the strength of the dielectric fluid. Under these conditions, current passes more easily between the two electrodes, and each spark causes the element to separate from the metal sheet.
After the current is passed through and the desired shape is achieved, manufacturers sometimes take a process called “flushing,” using a dielectric liquid to help remove any undemanding material or waste from the finished product.
Wire EDM Service Feature
Easy to handle complex parts machining
Intricate or complex shapes and patterns can be made using precisely focused electrical discharges. Wire EDMs can create different shapes, such as contours and holes, even on the hardest and most fragile materials.
Mechanic-free during the process
Unlike manufacturing processes that make heavy use of impact cut materials, wire EDM uses thermal discharge to cut parts. This means that the final product will not be deformed, twisted, or deformed in any way by the brute force in material removal.
High efficiency
When you use a wire EDM, you don’t have to use a lot of energy to cut even the toughest materials. Additionally, you will reduce material waste because the process only removes the target particles. Your cut kerf (cut width) is usually less than 0.015 inches. Also, you don’t need other machines for post-processing as this method provides precise and accurate cuts.
Accuracy and Precision
The best thing about Wire EDM is that your final product does not need to go through other processes such as grinding, honing, etc. This method provides a high level of accuracy and precision, especially on the smallest parts.
High Tolerance
Another benefit of Wire EDM is that you can achieve high tolerances no matter what material you use. You can easily achieve a tolerance of +/- 0.0005 inches with some machines with tolerances as low as a few microns.
Materials for EDM
Tool Steel
Stainless steel
Aluminum Alloys
Cooper
Titanium
Brass
Ready to get started your wire EDM machining project?