In the course of industrial development, many advanced machining methods have emerged. Wire-cut electrical discharge machining is one of them. Because of its tremendous advantages such as high precision, small kerf, and the ability to process highly complex workpieces, wire EDM has become an indispensable machining method in many industries. From medical devices to aerospace, from electronic equipment to medical devices, none of them rely on wire EDM. To help you better understand this technology, this article explores the applications and processing advantages of wire EDM in a variety of industries.
Table of Contents
wire EDM
Wire EDM is a special processing technology. The whole process requires the use of wire electrodes to discharge metal conductors.
A wire-cutting machine works by moving an electrode wire along a specified track for electrical discharge machining. It cuts the workpiece while discharging electricity. Unlike conventional machining methods, wire EDM is performed without direct contact with the workpiece. In this process, the electrode wire is used as the cathode and the workpiece acts as the anode. The power supply is then activated and a voltage is generated between the electrode wire and the workpiece electrode. When the electrode wire and the workpiece are far enough apart, the voltage will cause the liquid to breakdown. At the same time, a conductive loop is formed between the electrode wire and the workpiece, which is instantaneously discharged. The discharge process generates a sudden high temperature of between 10,000°C and 12,000°C. These temperatures can cause the metal workpiece to melt.
As the workpiece melts, the working fluid rapidly vaporizes and expands, which triggers an explosive shock wave. The entire process throws the melted and vaporized metal out of the discharge position. In order to keep the workpiece material removed, the discharge is continuously generated by a pulsed power supply.
Unlike mechanical cutting that removes material, wire EDM machines remove material without mechanical stress. It also has the advantage of easy processing of conductive materials with high strength. As a result, wire EDM machines are widely used in many industries.
Aerospace
In the aerospace field, there is often a need for high-precision and high-reliability parts, so the use of wire-cut processing is a good method. It can meet the high precision requirements of the aerospace field, and at the same time can also ensure a relatively high degree of reliability. For the aerospace field, wire EDM has become indispensable.
First, in engine manufacturing, wire EDM is able to machine complex shapes of turbine blades and impellers. These components often need precise shapes and internal cooling channels. They must endure extreme operating conditions: high temperatures, high pressures, and high speeds. For example, wire cutting precisely molds the curved shape of the blades. This shape ensures smooth airflow and boosts engine efficiency and performance.
In addition, wire EDM is used to manufacture structural components for aircraft. These parts are critical, such as wing connectors and fuselage frames. They have complex shapes and need extreme strength and precision. The use of wire EDM ensures the structural integrity of the aircraft and flight safety. For example, using wire EDM to make connectors that fit different parts well reduces stress. The use of wire EDM also improves stability.
Furthermore, some micro-parts in the spacecraft can also be processed using wire cutting. For example, the sensor bracket on the satellite, small propeller parts, etc., the use of wire cutting can carry out the processing of small size. These parts can also ensure high precision after processing.
In addition, some special materials in the aerospace field can also be processed using wire cutting. For example, for high-temperature resistant, high-strength titanium alloys, nickel-based alloys and other materials. These materials are often difficult to process. It is not easy to process using general traditional cutting, but it is relatively easy to use wire EDM to process the part shapes that meet the requirements.
In the case of an aero-engine, the turbine blades are finely processed by wire-cutting technology. In processing, we control the parameters strictly. This ensures the blade’s shape is precise to the micron or finer. The high precision of the blades is essential to the performance and reliability of the engine.
Medical
The requirements for precision and quality of medical devices are very high. Wire-cut processing technology has unique advantages in this regard. And wire EDM can meet these needs well. For example, scalpels, artificial joints, and braces need high precision and cleanliness.
In addition, wire EDM is also suitable for the manufacture of medical device molds. It can provide strong support for the manufacturing of medical devices and meet various processing requirements.
In the cardiovascular field, the making of devices like pacemakers and stents requires wire cutting. In particular, the tiny electrodes and connectors in pacemakers must transmit signals accurately. They also need to be very precise and stable. Wire EDM is able to process these tiny and precise parts, ensuring the proper functioning of the pacemaker.
In the field of dentistry, wire EDM is used for the production of metal brackets for dentures and components for implants. These components need to match the anatomy of the mouth in order to work properly. They also need to have good strength and durability. The precise manufacturing capabilities of wire EDM can meet the accuracy requirements of components in the dental field.
In conclusion, wire EDM tech will be used more in the medical industry. This is because of its high-precision machining capabilities. In the future, the use of wire-cut processing parts will be more to benefit people around the world.
Electronic
The electronics industry is seeing a trend. Products are getting smaller, combining more functions, and getting more precise. Electronic technology is always developing. Electronic components are getting smaller and the precision requirements are getting higher. Wire-cut processing technology is precise and stable. It plays a key role in making electronic parts.
For printed circuit boards (PCBs), we often see them in our life. Many printed circuit boards contain microvias and shaped holes. For the processing of these shapes, we can use wire-cut processing. As electronics get thinner and lighter, the lines and hole spacing on PCBs also shrink. This requires high processing accuracy. Wire EDM allows precise machining of microholes. Since the diameter of microvias is very small. So wire EDM ensures high density circuit layout and good signal transmission.
In addition, in semiconductor manufacturing, wire EDM can be used to cut silicon wafers. It is also possible to process some micro-structured parts. For example, in making integrated circuits (ICs), we must cut silicon wafers into chips. Wire EDM is a good way to do this. Wire EDM can provide high precision cutting results. It also reduces chip damage and defects, greatly improving the pass rate.
Automotive
When we see the car traveling on the main road, we may ignore its manufacturing process. But the use of wire-cut processing parts in the automobile above has many applications.
In the manufacturing process of automobile engine parts, camshafts, valve tappets and other parts in automobile engines not only have complex contours, but also have requirements for the precision of dimensions. Therefore, the use of wire EDM can accurately shape the contours of these parts. At the same time, it also ensures good engine performance in operation.
For the processing of automobile molds, the use of wire cutting processing is also a very good processing method. Common automotive interior parts molds, such as dashboards and center consoles, are vital to automobiles. Usually, in order to achieve high precision requirements, wire cutting is also used for processing.
In addition, there are also components such as control arms and steering knuckles in automobile suspension systems that are also processed using wire cutting. This is because complex shapes can be processed using wire EDM. The precision of the dimensions can also be well guaranteed.
Tool and mold manufacturing
In the field of mold manufacturing, wire-cut processing technology is widely used. In the manufacture of tools, wire cutting technology also plays an important role.
In the stamping mold manufacturing, wire cutting processing technology shows a significant advantage. Convex and concave dies in stamping molds usually have complex geometrical shapes, and even have high requirements for precision. For example, the manufacture of stamping dies for electronic equipment housings requires precise bending and punching in a very small space. Wire EDM is able to accurately machine the complex contours of mold components. These contours include sharp corners, narrow slits, and tiny bumps. By controlling the discharge parameters and the cutting path, the sharpness of the die edge on the one hand and the dimensional accuracy on the other can be ensured. This process is also useful for improving the quality and consistency of stamped parts.
Wire EDM technology also plays a unique role in tool manufacturing. The cutting edges and spiral grooves of special tools can then be processed by wire cutting. Examples include non-standard shaped milling cutters, drills and other tools. In addition, for tools customized for the processing of special materials in the aerospace industry, wire EDM is able to produce precise edge geometries and angles. The cutting performance of the tool can be improved through this machining method, which also increases its durability.
Other Industries Using Wire EDM
In addition to the above five common fields, there are also the energy industry and the instrumentation industry. This is because these industries also have higher requirements for precision. For example, the manufacture of precision parts in oil and gas extraction equipment also uses wire cutting processing technology. This includes parts such as specially shaped valves and seals.
Wire cutting is also used in the production of high-precision instrument parts. To ensure the instrument’s accuracy and stability, the impeller in the flowmeter and the sensitive element of the pressure sensor need wire cutting. This is needed to ensure measurement accuracy.
In summary, wire cutting technology has wide application in many industries because of its high precision and ability to process complex shapes. Especially, it is one of the better processing methods for parts with complex shapes and high precision requirements. As a supplier of parts processing for more than ten years, Yonglihao Machinery has a wealth of experience and expertise in the processing of wire EDM. If you still have questions about the processing of wire EDM, please contact us. We will provide you with professional answers at the first time.
Advantages of wire EDM in different industries
In different fields, the use of wire EDM has different processing advantages. First of all, due to the high machining precision of wire EDM, it is able to produce parts with very small tolerances. Therefore, in the aerospace field, the use of wire cutting processing is very important for the stable operation of aircraft. Especially in the extreme environment of high altitude or in space.
Secondly, for the automotive industry, wire cutting brings many benefits. It can produce fine shapes and structures for automotive stamping dies. And the same can be achieved for injection molds. Also, during the development phase of an automobile, wire EDM can quickly produce prototype parts.
In the medical field, there are also clear advantages to using wire EDM. Many components in the medical field have to meet high precision and individual requirements, which can be achieved using wire EDM. Because medical devices require high levels of hygiene and safety, the process of using wire EDM is relatively clean and free of contamination. In addition, WEDM meets strict medical standards.
Conclusion
With the above detailed introduction, I believe you have a good understanding of the industries in which wire EDM can be used. From the aerospace field to the medical field to the automotive industry, wire EDM has been used in a wide range of applications. We believe that in the future, science and technology will continue to develop. The accuracy of wire cutting will also keep improving. Wire EDM technology will also have more industries using this machining parts. If you need wire EDM machining, you can contact us. We will give you a free quote for your project right away. Then, we will help you with your machining. We especially look forward to hearing from you.
FAQ
There are limitations to WEDM, one is that the processing speed is slow and inefficient. Secondly, there are deficiencies in surface roughness, electrode wire loss and processing thickness. And the working environment and equipment requirements are high, and the cost is also higher.
Wire EDM has advantages and disadvantages compared to traditional machining methods. Its advantage is that it can process complex shapes and high-precision parts. For some materials with high hardness, it can also obtain good processing results. The disadvantage is that the efficiency is slightly lower than traditional methods. The processing effect is greatly affected by the conductivity of the material.
On the one hand, wire cutting machine tools need to regularly clean the machine surface, guideway and other dirt. At the same time, the various parts of the machine tool to do a good job of lubrication. Check and replace the key parts of the machine tool regularly. This prevents impurities from damaging it. For example, components such as coolant cartridges and molybdenum wires.