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, 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.
Reasons for choosing Wire EDM
There are a number of advantages to be gained by using wire EDM compared to conventional machining methods. These advantages are difficult to achieve with conventional machining methods. Therefore, for many electrically conductive raw materials, processing using wire EDM is one of the best methods.
High machining accuracy
Traditional cutting methods such as turning and milling are often difficult to achieve the high precision that wire EDM can achieve. This is because of the impact of tool wear, machine accuracy and other factors. Wire EDM can achieve micron-level precision control. Accuracies of ±0.001mm are not uncommon in some high-end applications. For example, when manufacturing precision gauges, wire EDM ensures accuracy and consistency of scales. Conventional machining, on the other hand, can suffer from a lack of precision due to cumulative errors. It is for this reason that wire EDM is widely used in industries such as aerospace, mold making, and medical devices.
Ability to process complex shapes
Traditional machining has greater difficulties in processing complex inner contours, sharp corners, narrow slits and other shapes. Some may require multiple processes and complex jigs and fixtures. Wire EDM processing is not subject to these limitations and can easily cope with a variety of complex shapes. Whether it is a two-dimensional or three-dimensional complex contour, wire EDM can handle it. In the case of an injection mold with complex internal runners, for example, which is difficult to achieve with conventional machining, WEDM can accurately process the desired shape.
No need to consider material hardness
In conventional cutting, the hardness of the material significantly affects machining efficiency and tool life. For high-hardness materials, such as cemented carbide and hardened steel, machining is difficult and costly. Wire EDM, on the other hand, is not affected by material hardness and can process both extremely hard and softer materials with the same efficiency. This allows for greater flexibility in the selection of materials. For example, when processing inserts for molds, even if the material hardness is very high, wire EDM can be completed successfully.
Less chip force generated
Milling and turning are conventional machining methods. They may add stress that deforms the workpiece. Wire EDM processing corrodes the material through electric spark discharge and does not generate mechanical stress. Therefore, workpiece deformation can be effectively avoided. For example, processing thin-walled aerospace parts, traditional processing may lead to deformation of the parts to affect the use, while wire cutting can ensure its shape accuracy.
Can obtain good surface quality
After the completion of wire cutting processing, usually gets a good surface finish. Because the discharge energy of the pulse power can be precisely regulated during the wire-cutting process. By reasonably setting the pulse width, pulse interval, and other parameters, the processed surface is smoother and flatter. The reason for this is that a smaller single discharge energy can be realized, thus reducing the thermal effect on the workpiece surface and the amount of material removed. The surface finish obtained is usually very high, which also reduces the subsequent polishing and grinding processes and can improve productivity. For example, in the manufacture of components for optical instruments, good surface quality contributes to improved optical performance.
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
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.
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.
Wire EDM machines require regular cleaning and maintenance. The molybdenum wire needs to be inspected and the machine calibrated regularly.