Don't Waste Time! 4 Facts Until You Reach Your Wire Cut EDM Machine
Oct. 12, 2021
Wire EDM has been around since the late 1960s. Machining plays a leading role in accurately cutting workpieces weighing more than a few thousand pounds.
1.What is EDM?
EDM is a cutting process used on metals. A wire is passed through the part to be cut, breaking down the metal. But how do you cut metal through a wire? Here a charged brass wire is used, which runs in a fully automatic and controlled manner. The wire comes close to the workpiece without touching it. The gap between the two is almost as thin as a human hair. The method does not require any mechanical force, similar to the laser cutting process. The metal/workpiece and wire are completely submerged in the dielectric fluid, or the fluid itself washes over the metal and wire. The fluid helps to remove the broken particles from the metal. During this process, sparks are created to cut the metal; even though the broken metal particles are small, the sparks discharge approximately 100,000 times in one second.Wire EDM helps cut and shape the metal into intricate designs in a way that no other technology can. The precision of this unmatched, fully automated system helps deliver consistent results every time.
2.What materials can be wire cut with EDM?
Any electrically conductive material such as steel, titanium, aluminum, brass, alloys and high temperature alloys can be cut using the EDM wire cutting method. With its precision, EDM wire cutting technology has become a routine cutting method in a wide range of industries. Machine parts, logos and other metals can be easily cut and manufactured using EDM wire. The production of parts or their prototypes using EDM wire depends on the thickness and size of the part to be cut and the length of the cut to be created.
3.Advantages of EDM
●Accurate 2-axis cutting for small parts
EDM wire cutting is a very precise method for the right applications, such as 2-axis cutting of small parts with tight tolerances for high volume production. For example, for mass production of pins, probes and other small solid metal parts less than 0.020 inch (0.50 mm) in diameter, the advantages of EDM include 1) highly repeatable lengths with no end distortion, twisting or delamination. 2) far better cost effectiveness than methods such as laser cutting.
For small diameter solids, EDM also offers extremely high concentrated trend measurements for very high Ppk/Cpk values. For example, EDM can not only cut 0.004" (0.1 mm) diameter precious metal wire to 1" (25 mm) lengths, but can also do so while achieving length tolerances of ±0.001", rounded ends and Ppk well above the standard minimum of 1.33.
●Burr-free cutting of various diameters
EDM wire cutters can cut diameters ranging from a few thousandths of an inch to several inches, and lengths from 0.5 inches (12 mm) to 18.0 inches (450 mm), with high dimensional accuracy. Because no grinding wheels or saw teeth are involved, EDM wire cutting procedures generally leave no burrs, and kerf widths are typically 0.004" to 0.012" (0.1 to 0.3 mm).
Wire EDM is used to machine a variety of fixtures, plastic molds, powder metallurgy molds, and other parts with 2D and 3D surfaces or combinations. It can also cut various sample plates, magnets, silicon steel sheets, semiconductor materials or precious metals. In addition, it is capable of fine machining, incorrect groove shapes or machining standard sample part defects, and is widely used in electrical engineering, valuable machine tools, light industry, and military industry.
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