In modern manufacturing, choosing the right machining method is important. The right machining method is the key to ensuring product quality and productivity. Traditional machining methods include milling, turning, and drilling. They are widely used and have mature technology. But, in some specific fields, they can’t meet the rising requirements for precision, complexity, and material diversity. At this time, what kind of machining method should be chosen? Wire EDM, as an advanced processing technology, can solve this problem. Due to the unique advantages of wire EDM, it is fast becoming the first choice for many high-precision manufacturing needs.
In the following section of this article, we will talk about the definition of wire EDM and how it works. This will be followed by the specific reasons for choosing wire EDM and the applications. In addition, there are limitations and cost efficiencies of wire EDM. In short, this will help you understand more about wire EDM.
Table of Contents
What is Wire EDM?
Wire EDM, also known as EDM. It is a special machining method that utilizes the thermal energy generated by electric spark discharge to etch away metal materials. Wire EDM has big advantages over traditional machining. It’s better for high precision, complex shapes, and many materials, and it avoids stress.
How does Wire EDM work?
The basic principle of wire EDM is material removal from the workpiece using electric spark discharge.
In wire EDM, a moving wire (usually molybdenum or copper) acts as an electrode and is fitted to the machine tool’s wire traveler and moves along a predetermined trajectory. The workpiece is on the table and connected to the negative terminal of the power supply. The wire is connected to the positive terminal of the power supply.
When the pulse power source discharges, it makes an immediate electric spark between the electrode wire and the workpiece. The spark’s high heat can melt and vaporize tiny areas on the workpiece’s surface, removing material.
Overview of Wire EDM and Conventional Machining
Wire EDM is an innovative manufacturing method. It utilizes electric sparks to break down conductive materials with extreme precision. In contrast, milling, turning and drilling are traditional machining methods. They use physical cutting equipment to remove material. Therefore, when machining extremely hard materials and challenging designs. Conventional machining can be problematic due to tool wear and accuracy limitations.
Both processes are critical in manufacturing. Wire EDM can provide high-precision and quality solutions for specific tasks. Traditional machining, on the other hand, can provide diverse solutions for a wider range of applications.
Comparative Analysis Based on Industry Characteristics
The following is a comparison of the two machining processes.
Precision and Accuracy
Wire EDM offers unrivaled precision. It is the best choice for producing complex and precise parts. Wire EDM is capable of producing high-quality and complex products with extremely tight tolerances. On the other hand, conventional machining is capable of precision cutting though. However, it often lacks the fine detail and precise tolerances that wire EDM can provide.
Material Versatility
Wire EDM is very effective in cutting hard materials such as titanium, tungsten, and super alloys that are difficult to machine using standard methods. On the other hand, conventional machining is much more versatile in terms of operation. It is capable of performing a variety of operations on more diverse materials such as wood, plastics, and metals.
Cost and speed
For larger, simpler projects, conventional machining is usually faster and less expensive than wire EDM. This is because conventional machining has higher material removal rates and lower operating costs. On the other hand, wire EDM is slower and can be more costly. However, wire EDM is still very important for complex parts that require high precision and superb workmanship.
Surface Finish
Wire EDM is known for producing high-quality surface finishes. As a result, this process usually requires no further finishing. This high-quality surface finish is essential in applications where smooth surfaces and precise proportions are required.
In addition, conventional machining can produce good results. However, it may require additional processes such as grinding or polishing. It is then possible to achieve the same level of smoothness and quality as with wire EDM.
When to Choose Wire EDM over Conventional Machining?
Both machining processes have their own advantages. Therefore, we need to make a choice based on the needs of a particular application. The following are nine specific situations in which wire EDM should be chosen:
When Sharp Internal Corners Are Required
Wire EDM is very good at machining sharp internal corners. This assumes, of course, that the proper wire type, tension, and feed conditions are used.
Traditional CNC machines have difficulty machining sharp or square inside corners. This is because the cutting tool is usually rounded, leaving rounded corners (radii) on the workpiece. There are some ways around this problem though. For example, using square-end mills and single-sided dark cuts. However, machinists usually accept the need for rounded inside corners.
On the other hand, the wire used in wire EDM is also round. However, it is much finer than CNC cutting tools and can produce almost square inside corners. With wire EDM, the radius of the corners can be reduced to 0.005 inches.
When Extra Deep Cuts Are Required
When very deep cuts are required, longer cutting tools are used on conventional CNC machines. However, tools with excessive L/D ratios can chatter, resulting in poor-quality machined parts.
Because wire EDM is vibration-resistant, it is a viable solution for making deep cuts. In most cases, Wire EDM can easily machine holes with length-to-diameter ratios as high as 20:1. In addition, in some cases, this ratio can be as high as 100:1.
When Working with Extremely Hard Materials
Wire EDM is often used for machining molds and even machine tools. These items are usually made of extremely hard materials such as hardened steel or tungsten carbide. As a result, it is extremely difficult for conventional CNC machine cutting tools to penetrate these materials.
One advantage of wire EDM is that the hardness of these metals does not affect the tolerances of the machined part. Other metals that can be machined using wire EDM include Hastelloy (a nickel-molybdenum alloy), titanium, and Inconel.
When Parts Require Mirror Polishing
The surface finish of wire EDM workpieces is very high. As a result, an excellent mirror finish can be obtained without additional processing using the wire EDM process. Importantly, WEDM does not produce a “layered”, oriented surface like conventional machining.
Another way to achieve a mirror finish is to mix a fine abrasive powder into the dielectric fluid. This produces an effect similar to sandblasting. However, this effect is produced during the process, not after.
All-weather Production
However, this is a concern for manufacturers rather than engineers. However, wire EDM offers significant opportunities for automation and unattended or “lights out” manufacturing.
WEDM is more predictable and less prone to errors and interruptions than conventional machining. It is therefore possible to automate wire EDM machines. This can allow them to run 24/7 without supervision.
If manufacturers can automate the loading and unloading of workpieces (and electrodes). Then the manufacturing workflow will be efficient and automated.
When Manufacturing Molds
Wire EDM is sometimes preferred over CNC machining in the manufacture of molds and dies. This is because it can accurately cut solid metals such as tool steel. It is possible to use a CNC milling machine or an EDM molding machine first, and then use a wire-cutting machine for detail or depth cutting.
When Precise Tolerances Are Required
Wire EDM simplifies precision machining by allowing very tight tolerances to be achieved. Importantly, since there is no physical contact, the workpiece is less likely to be deformed by EDM.
With multiple passes, wire EDM tolerances can be as close as +/- 0.0002”. However, in order to achieve the highest precision, cutting speeds must be greatly reduced.
Material saving
Due to the use of wire electrodes for machining, wire EDM can minimize material waste. Especially for the processing of precious materials, it can significantly reduce costs. For example, when processing some rare metal parts, it can maximize the use of raw materials.
No need for molds and tooling
Traditional processing in mass production, often need to make special molds and tooling, increasing the cost and preparation time. Wire EDM eliminates the need for complex molds and tools. Not only can it be used to manufacture single pieces or small batches, but it can also respond quickly to production needs.For example, customized mechanical parts production, wire EDM can be directly based on the design drawings for processing, without the need to prepare molds in advance.
In summary, in addition to the above reasons for choosing wire EDM, there are more advantages. These include a wide range of use and high automation. With the continuous development of technology, it is an indispensable processing method in many high-end manufacturing fields. Yonglihao Machinery has more than ten years of processing experience in wire cutting processing. It not only has first-class processing equipment, but also has professional processing methods. If you still want to know more or have processing needs, you can contact us.
Application of wire-cut electrical discharge machining
Wire EDM as a very mature processing technology. It has been widely used in many fields. These fields are familiar to us.
Aerospace
Since the aerospace field requires very high precision, wire EDM is common in this field. It is commonly used to cut aircraft parts and engine components. For example, engine blades, turbine disks, and aerospace structural components. Through wire EDM, the dimensional and shape accuracy of the parts can be ensured to meet the high standards in the aerospace field.
Mold manufacturing
In the field of mold manufacturing, wire EDM can be used to produce stamping molds, injection molds and die casting molds. In stamping mold processing, it is used to make molds for stamping parts. These parts include automotive coverings and electrical enclosures. For example, wire cutting can process the complex surfaces and small structures in automobile door stamping molds. It can also process the molds of injection molded products in plastic injection mold production. For example, plastic toys, cell phone shell mold cavity. And die-casting mold processing applications, it is in the automotive engine block die-casting mold in the cooling waterway and complex cores can be used to wire cutting for processing.
automotive electronics manufacturing
Automotive electronics manufacturing field on the precision requirements are also very high, so also often use wire cutting for processing. Especially the processing of some materials with high hardness and conductive parts, wire cutting can be a good choice. It is used for cutting automobile body panels, chassis and other parts. Some parts in the transmission system, such as gears and bearing components, due to the need for high precision and wear resistance, wire cutting is also very suitable.
Medical Device Manufacturing
Wire EDM is very precise. It ensures that medical devices meet the strict requirements of the medical industry. For example, in the case of surgical blades and miniature pliers, wire EDM can process very small and precise tools. In addition, such as artificial joints and dental implants, wire EDM ensures high precision and biocompatibility.
Limitations of Wire EDM
Although we widely use wire EDM in many fields, it is imperfect. It also has some limitations:
Relatively slow machining speed. Compared to traditional cutting methods, wire EDM processing speeds are usually slower. Especially when large amounts of material need to be removed, its efficiency may not be sufficient for mass production. For example, wire EDM may not be the first choice when a large amount of material must be removed to manufacture large molds.
Requirements for material conductivity. Generally, only materials with a certain degree of conductivity can be processed, and non-conductive materials cannot be processed. This limits the application of wire EDM in some special material fields.
The processing size is limited. Restricted by the structure of the machine tool and the length of the electrode wire, wire-cutting processing in the processing of certain limitations on the size. It may not be suitable for machining large-size parts.
Development trend of Wire EDM
With the progress of technology, the precision of wire EDM machine tools is constantly improving. In the future, wire EDM will see even higher machining accuracy. This will be a great boost for applications requiring extremely high precision, such as aerospace and semiconductor manufacturing.
Secondly, improving processing speed is an important direction in the development of wire cutting technology. By tuning discharge parameters and upgrading power supplies. Also, by using advanced control algorithms. This will significantly speed up modern wire-cutting machines.
In addition, with the help of advanced sensor technology, artificial intelligence and machine learning algorithms, wire cutting processing will be more intelligent and automated. Loading and unloading systems will be automated. Operation will be unmanned. This will be the norm for future wire EDM applications.
Summary
This article has explored knowledge related to wire EDM. In particular, the reasons for choosing wire EDM were discussed. Wire EDM has significant advantages in terms of precision. It is hard to achieve micron-level accuracy with conventional machining. The ability to do so is useful for making precision parts. If you have a project and are unsure if wire EDM is an option, contact us. We can provide you with professional Wire EDM Machining Services to meet your part machining needs.
FAQ
What materials can be processed by Wire EDM?
Typically, wire EDM can be used to process metallic materials, carbide, high-temperature alloys and magnetic materials. However, materials with poor conductivity generally cannot be processed by wire EDM. We have also put together an article on which materials can be wire cut to help you better address this query.
What are the advantages of wire cutting over laser cutting?
Wire cutting has unique advantages in terms of high precision, complex geometry, processing of high hardness materials and no heat affected zone. Laser cutting is more advantageous in terms of speed and processing of non-conductive materials.
What are the maintenance requirements for Wire EDM machines?
Wire EDM machines require regular cleaning and maintenance. The molybdenum wire needs to be inspected and the machine calibrated regularly.