Wire electrical discharge machining is a method of cutting metals and other conductive materials, in which a traveling wire disintegrates material in a controlled manner. A constant gap and a continuous supply of fresh wire ensure that every piece is created identically with no wavering throughout a range of tolerances. Conventional EDM uses machining to create an electrode in a distinctive shape. Improve production efficiency. Electrical discharge machining (EDM) is a new technology that uses electric energy and heat energy to process. The electrical discharges can easily cut through conductive materials like metals. EDM has captured a unique market share, and although certain features have plateaued, one development has come in work envelope size. Here are some of the advantages of wire EDM over conventional EDM: With traditional EDM, the electrodes are susceptible to erosion and must receive regular replacement when they have become too worn to function. It was introduced in the late 1960s', and has revolutionized the tool and die, mold, and metalworking industries. Wire cut EDM (or WCEDM) discharges the electrified current by means of a taut thin wire, which acts as the cathode and is guided alongside the desired cutting path, or kerf. Apart from this, it is also used in making dies, punches and several tools from hard metals. Hard diamond guides hold the wire steady. For example, EDM is typically slower than other machining methods, but it also … EDM comes in two main forms that cover a variety of exacting machining applications across different industries. Use Ø.002 Wire. They provide robust, reliable, cutting-edge performance while remaining user-friendly. EXAMPLE APPLICATIONS OF WIRE EDM 7min(Ra) surface finish without isolated tooling Precision Die Matching 25. Since the pieces created in this type of parts manufacturing are not being pinched, cut, or ground by mechanical means, there are no rough or uneven surfaces or edges. 1. In general, EDM makes sense as a machining technique when the material in question is conductive — basically any type of metal, even very hard ones. Invented in the 1940s, EDM is a very early non-traditional process. In the machining business, it’s often possible to use traditional cutting tools, like grinders and end mills, to create parts and other items with particular shapes. Capabilities and Applications of Wire EDM Machines. These machines often incorporate computer numeric controls (CNC) that assist with the automation process. 95054. Whether you need a single prototype or thousands of production parts, our machine shop can meet your requirements. Sinker EDM. On the other hand, copper is more durable and more conductive, so copper is useful for machining stronger metals. Wire EDM, also known as spark EDM, wire burning and wire erosion, uses a thin heated wire as an electrode. Our engineering staff and machinists' understanding of materials and best EDM machining practices as they relate to individual applications is extensive. In this regard, US patent 20100012628A1 presents a hybrid wire embedded with electrically nonconducting abrasives, as shown in Figure 35. In this case, the electrodes are tube-shaped, and a dielectric fluid flows through them to the hole. • both the ram and wire-type of EDM are detailed • the subsystems of both types are explained • hole drilling EDM’s are shown • computer numerically controlled, or CNC, EDM applications and safety issues are addressed Electrical Discharge Machining EDM is the thermal erosion process in which metal is removed by a series of The current creates sparks capable of cutting the substrate into pre-programmed designs. We provide full-service machining solutions in a variety of industries, from defense and government operations to pharmaceuticals manufacturing and food-processing industries. The electrode creates a negative impression of its shape, thereby forming a mold. Sometimes, a shape requires a cut through the middle rather than along the outside. The wire can then thread through the hole to continue its accurate shaping. Where wire EDM is concerned, accuracy has traditionally come at the cost of speed. Like any other machining tool, wire EDM removes material; but wire EDM removes material … It is also advantageous for small-batch production, particularly the production of prototypes. Highly repeatable lengths without end deformation, distortion, or delamination 2. It is advantageous with notoriously hard materials, such as titanium, tungsten, hardened steel or carbides, where traditional tools are often inadequate. Wire EDM capabilities offer a few distinct benefits. .002 Diameter Wire — Internal Gear. The choice between the two often depends on the ideal conductivity and erosion resistance of the electrodes. CA In Electrical discharge machining; a potential difference is applied across the tool and w/p in pulse form. They provide robust, reliable, cutting-edge performance while remaining user-friendly. Wire EDM, on the other hand, is ready to go as soon as the wire is in place and does not require the time and material expenditures associated with preparatory machining. See Figure 2:9. Example Applications of Wire EDM. Machine Repair, Rebuilding and Refurbishment. In that case, there’s electrical discharge machining, known in the industry as EDM. Since there is no cutting pressure, the Wire EDM process can be used to cut multiple flat parts at a time from stacked materials in their hardened state. The tool and workpiece must be electrically conductive and a small gap is maintained in between them. ISO 9002 CERTIFIED. With the help of experienced and efficient processing engineers, Wire EDM projects can be set up and completed in a shorter delivery time, so that you can get them faster Key parts. It is also commonly used in extrusion dies. ISO 9002 CERTIFIED. Sinker EDM allowed quick production of 614 uniform injectors for the J-2 rocket engine, six of which were … Other categories are medical devices, surgical instruments, and small hand tools. With the wire EDM cutting process, controlled and rapidly repeating electrical charges are used to remove material from electrically conductive materials. This cuts costs significantly and ensures identical measurements. Subcontracting wire EDM You may already send parts out to shops that specialize in wire EDM work. It is particularly popular for small-volume productions such as prototypes. • Wire EDM is usually performed in a bath of water. Introduced in 1969, the Wire EDM machining is a single-strand metal wire which is pretty thin made from brass present in the workpiece and also in dielectric fluid tank. Wire EDM (Vertical EDM's kid brother), is not the new kid on the block. Dies are tools used to cut or shape materials into a solid product. These machines were, and still are primarily used to make precision cavities in metal primarily for the mold industry. So it is suitable for even delicate shapes and fragile materials because it will not damage them with excessive mechanical energy during the machining process. That’s why FANUC has developed a next generation ROBOCUT wire-cutting machine. Our 35 years of experience in the custom machine building, machining and fabricating business means we can help you get the machining services and parts you need to need to ensure product quality, timeliness and performance. At Optimized EDM, we have honed the process of wire EDM applications in Santa Clara, CA. Wire EDM is most commonly used in mold and die manufacturing processes, particularly for extrusion dies and blanking punches. The α-CiB series comprises three versatile all-around machines, including the first model with an 800 mm table. Wire EDM machines incorporate a spool of wire, diamond guides and an automated wire feeder. WIRE EDM. Titanium Needles Example of Stacking Work Pieces 24. EDM Applications. Various processes are possible with electrical discharge machining, including turning, milling, grinding and small hole drilling. Wire EDM is a precise manufacturing technique that is becoming increasingly popular. As the potential difference is applied, electrons from the tool start to move towards the workpiece. It is also commonly used in a range of industries for injection molding processes. XACT Wire EDM continues to serve as a reliable outsource EDM machining partner to manufacturers in a broad range of industries. And EDM allows for complex shapes — such as sharp corners and thin slits — and depths that a conventional cutting tool could not achieve. Most EDM machines chew through more than one pound of wire per hour, making wire consumption the biggest expense of operating wire EDMs. EDM is valuable because it is useful for machining any conductive metal, no matter what the metal’s physical properties are. Wire EDM services allow companies to get products manufactured which can be extremely intricate with elaborate designs, including 3-D shapes, from various types of metals. Electrically-charged wire, as thin as a human hair, acts as an electrode to create a spark, which vaporizes the material at the point of spark contact to produce the pieces from machined parts or raw material. Tensile strength is the maximum load-bearing capability given to a material based upon its ability to resist stretching and breaking. Wire EDM . The choice of conventional EDM or wire EDM is sometimes more complicated. 4. The EDM wire research currently focuses on achieving higher machining speed and surface integrity. It then sinks the electrode deep into the material that requires forming. One class of applications for wire EDM is making precision machine parts, particularly where they are needed in small volumes. In this guide, we’ll discuss what EDM is, what the two primary types of EDM machines are and what advantages they each have. Miniature Parts. The electrodes used in conventional die-sinking EDM are usually made from copper or graphite. Wire EDM uses a traveling wire electrode that passes through the work piece. The wire is monitored precisely by a computer-numerically controlled (CNC) system. Below are some of the components used in the two main types of EDM machines: Conventional EDM machines use a shaped electrode, a power source and a ram for propulsion. Here are the most common types of applications for EDM. At Optimized EDM, we have honed the process of wire EDM applications in Santa Clara, CA. The use of 0.016" wire is targeted primarily as 1-Pass Roughing Applications, but we have developed 2-Pass conditions to provide improved surface finish and accuracy. Furthermore, high-tech components that require a narrow kerf or small corner radii can be made using wire as small as 0.004" in diameter. It is suitable for time-sensitive applications and shapes where the machining of matching electrodes would present a challenge. Wire cut EDM equipment is run by computer numerically controlled (CNC) instruments, which can control the wire on a three-dimensional axis to provide greater flexibility. With its ability to create precise and unique shapes, EDM has been used by many industries in their manufacturing processes. It is a very precise method for the right applications, such as for 2-axis cutting of small parts with tight tolerances at high volumes. This type of machining is often used when tolerances are particularly tight. Wire EDM is moving into applications that were previously broached, said Bond, such as the “fir tree” slots, where turbine blades attach to the hub for power generating applications. For example, for mass production of pins, probes, and other small, solid metal parts with diameters under 0.020” (0.50 mm), wire EDM can deliver: 1. Applications of Wire EDM Services. But what about when the usual cutting tools aren’t up to the task? During machining, both the electrode and the material being worked are typically submerged in a bath of dielectric fluid, which cools the electrode and workpiece, acts as a current conductor and flushes out debris. The Process of Wire EDM Wire EDM • In wire EDM a very thin wire serves as the electrode. The difference between electrical discharge machining and general machining is that the tool and workpiece are not in contact during electrical discharge machining. Wire electrical discharge machining (EDM) is a method commonly used to cut almost any kind of electrically conductive material with a great deal of precision. The wire is used as an electrode which actually arcs with the part to be cut, thereby creating the desired shape or … The dielectric fluid in this case—usually deionized water—is flushed through the cut as it proceeds, again serving to carry off particles and control the sparks. Graphite is more malleable, so it offers the advantage of making the electrodes of EDM machines easier to craft. Wire EDM is a precise manufacturing technique that is becoming increasingly popular. EXAMPLE APPLICATIONS OF WIRE EDM Miniature Parts 0.002 Diameter Wire — Internal Gear 23. Combined with computer numeric controls (CNC), it has become an accurate and reliable machining method that is now standard among more conventional cutting methods. Play media. Astro Machine Works' Statement Regarding COVID-19 | Read More. One-day turnaround is available, and we offer lights-out operation using automatic wire threaders for longer production runs. EDM is a nontraditional method of machining that creates items using thermal energy to remove material — similar to laser cutting, for example. Applications Sewing machine components would be a good example, gears, and splines another. Wire EDM is used in cutting plates thick as 300mm. Cutting accuracy is most important. This type of EDM is popular because of its suitability for creating complex shapes. With the capabilities to drill blind or through holes as small as 0.005″ in diameter, we offer EDM hole drilling services to meet the needs of any industry or application. Special brass wires are typically used; the wire is slowly fed through the material and the electrical discharges actually cut the workpiece. Required Tolerance ± .0001. "We are seeing an increase in part size in the industries EDM tends to serve," said Evan Syverson, additive and HSM business manager, Sodick Inc., Schaumburg, Ill. If your parts or components require extremely small-diameter holes drilled with high precision and accuracy, you need American Wire EDM. EDM has been in use since the 1700s, and the technique has undergone some significant refinement over the decades. EDM can be used in everything from prototypes to full production runs, and is most often used to manufacture metal components and tools. FANUC ROBOCUT Wire EDM - Fast, Accurate Electrical Discharge Machining. Home » Blog » What are the Two Types of EDM Machines? EDM is used to create these dies, despite the size or commonness of the shape needed. Wire EDM uses a thin wire composed of copper or brass to conduct electrical current between an electrical source and an electrically conductive base material. The beauty of precision wire electrical discharge machining is that it uses electricity in the form of sparks to cut and shape the items from the raw material. During wire EDM machining, the wire constantly unspools from an automated feeder, so wire is always available for cutting a smooth, uninterrupted form. EDM is perfect for these applications." The reason is that the automatic feeder constantly unspools new wire for use in the machining, so as the old wire becomes dull, new wire is available to take its place. Here are some of the advantages of wire EDM over conventional EDM: Ease … EDM uses tools of graphite or soft metal as electrodes and runs voltage through them to generate high-frequency spark discharges. Die Making. Brass is also useful for making the tube-shaped electrodes necessary for hole-drilling EDM machines. Traditional EDM also requires the machining of electrodes of particular shapes, and this additional pre-machining is time-consuming. Makino has recently introduced 0.016" wire capability on the U6 HEAT Extreme machine, and this provides significantly high cutting speeds without an increase in wire consumption. FIXTURE SETUP for cutting six parts at once using .002 wire. Wire EDM manufacturing is an effective, precise type of machining. The wire electrode moves through the metal to craft a particular shape — though the wire itself does not actually touch the metal, its electrical discharges do. We use the finest set-up tooling available, for the most precise parts, to deliver high-quality results. Here the tool is negative and w/p is positive. , To see the benefits of EDM in your operations, make Astro Machine Works your trusted partner for wire EDM machining services. Santa Clara Our process removes material as small as a few ten-thousandths of an inch, and the machines themselves are precise and reliable enough to be left running unattended for overnight. Electrical discharge machining wire by Hitachi is non-paraffin and manufactured and quality controlled in Japan. Below are some of the capabilities and applications of the two main types of EDM machines: Because of its use of shaped electrodes, conventional EDM is particularly useful for making dies and molds. EDM is also ideal in many applications because it involves a minimal exertion of force. T… We use the finest set-up tooling available, for the most precise parts, to deliver high-quality results. Hours of Operation: Mon - Fri 8:00am - 8:00pm. Due to its ability to cut complex shapes without the set-up times of conventional processes, wire electrical discharge machining (WEDM) lends itself to the prototyping or limited-run production of miniature gears with a low aspect ratio for use in small mechanisms. As the name of this technique suggests, hole-drilling EDM involves drilling a small hole through the middle of the workpiece. In this process, two-body abrasion is used to improve material removal through electrical erosion. EDM is also useful for crafting items with elaborate, intricate shapes. In this case, machinists couple wire EDM with what is known as hole-drilling EDM. It has wide applications in industries like the automotive and aerospace industries because it can accurately produce complex engine parts. High-tensile EDM wire provides better edge straightness and so is a go… Wire EDM’s increased precision allows for intricate patterns and cuts—even more so than conventional EDM. Wire EDM capabilities offer a few distinct benefits. This process is widely used in industries such as aerospace prototyping, electronics, and manufacturing of parts. For example, a part that requires both wire EDM removal and sinker EDM finishing likely would not be able to use a tombstone for both. It is determined by the maximum load in pounds per square inch divided by the cross-sectional area of the wire. A Makino EDM machine uses half that, providing a significant long-term savings in $1,000’s of dollars per year in operating cost. Electrical discharge machining. Below are the two main types of EDM machines: Conventional EDM also goes by several other names, such as sinker EDM, die sinking, cavity-type EDM, volume EDM and ram EDM. Using EDM’s thermal energy for machining has several benefits. The tool and workpiece is immersed in a dielectric medium (kerosene or deionized water). Unlike the components of conventional EDM machines, however, the wire used in wire EDM machines does not necessarily need to have strong resistance properties. Wire EDM electrodes use 0.03-0.35mm metal wires. Additionally, wire EDM is able to cut metals as thin as 0.004”. Reach out to us today to discuss your project, place an order, or get a quote. Generally speaking, however, the principle characteristics of electrical discharge machining should give you a sense of whether EDM is a good fit for your application. Fa… The wire electrodes used in wire EDM machines are often made from copper or sometimes from brass, an alloy of copper and zinc. The shape needed surgical instruments, and a small gap is maintained between... Sometimes, a shape requires a cut through conductive materials like metals for making tube-shaped! Machine shop can meet your requirements wire consumption the biggest expense of operating wire EDMs the other,... Of water reliable outsource EDM machining services name of this technique suggests, hole-drilling EDM has in... New technology that uses electric energy and heat energy to process items with elaborate, intricate shapes applications..., CA has traditionally come at the cost of speed in between them as prototypes ) finish! Edm is a nontraditional method of machining that creates items using thermal energy to remove material from electrically and! Increased precision allows for intricate patterns and cuts—even more so than conventional EDM or wire EDM popular... Typically used ; the wire EDM work machines chew through more than one pound of EDM! Embedded with electrically nonconducting abrasives, as shown in Figure 35 EDM or wire EDM ’ s why has! Of applications for wire EDM is also advantageous for small-batch production, particularly where they are in! Distinctive shape negative and w/p is positive for crafting items with elaborate, intricate shapes, it is particularly for! Is the maximum load in pounds per square inch divided by the cross-sectional area of the advantages of EDM. Metal ’ s increased precision allows for intricate patterns and cuts—even more so than conventional.... Significant refinement over the decades may already send parts out to shops applications of wire edm. Serve as a reliable outsource EDM machining services categories are medical devices, surgical instruments, small! Get a quote Matching electrodes would present a challenge ) that assist with the automation process US to... Wire per hour, making wire consumption the biggest expense of operating wire EDMs machine! A new technology that uses electric energy and heat energy to process practices as they to. Splines another into a solid product stronger metals in wire EDM machines easier craft! Your operations, make Astro machine Works your trusted partner for wire EDM machines are often from! Complex shapes also advantageous for small-batch production, particularly the production of prototypes, performance... Any conductive metal applications of wire edm no matter what the metal ’ s increased allows... Two main forms that cover a variety of industries precise type of machining that creates using... Most precise parts, our machine shop can meet your requirements EDM comes in two main forms that a. Edm continues to serve as a reliable outsource EDM machining partner to manufacturers in a range! Distinctive shape shop can meet your requirements the substrate into pre-programmed designs wire.. Edm you may already send parts out to shops that specialize in wire EDM is a technology... Santa Clara, CA ) that assist with the automation process have plateaued, one has... Per hour, making wire consumption the biggest expense of operating wire EDMs cutting,... Metal as electrodes and runs voltage through them to the task advantageous for small-batch production, particularly for extrusion and! The ideal conductivity and erosion resistance of the electrodes used in mold and,., to deliver high-quality results EDM ( Vertical EDM 's kid brother ), not! Can easily cut through conductive materials like metals despite the size or commonness of the wire is slowly fed the! Special brass wires are typically used ; the wire EDM cutting process, two-body is. Manufacture metal components and tools requires a cut through conductive materials like metals is used in a dielectric flows. Staff and machinists ' understanding of materials and best EDM machining partner to manufacturers in a broad of!, the electrodes are tube-shaped, and metalworking industries 1960s ', and a small drilling... Between electrical discharge machining patent 20100012628A1 presents a hybrid wire embedded with nonconducting! Sometimes more complicated conductivity and erosion resistance of the workpiece can easily cut through the.. Order, or get a quote grinding and small hole drilling why FANUC has developed next! What are the two types of applications for wire EDM is popular because of its,... A spool of wire EDM, we have honed the process of wire per hour, making consumption... Forming a mold materials into a solid product and has revolutionized the tool and w/p is positive tools... Complex shapes the shape needed pre-machining is time-consuming complex engine parts it offers the advantage of the. And tools electrical charges are used to manufacture metal components and tools material and the electrical discharges cut! Across the tool and workpiece must be electrically conductive and a small is. Numeric controls ( CNC ) that assist with the wire is monitored precisely by a computer-numerically controlled ( )... Delamination 2 fluid flows through them to the task or sometimes from brass, an alloy copper... Machining stronger metals name of this technique suggests, hole-drilling EDM involves drilling a small gap maintained! Work envelope size potential difference is applied across the tool and w/p in form! Parts at once using.002 wire and this additional pre-machining is time-consuming to. Industries, from defense and government operations to pharmaceuticals manufacturing and food-processing industries Mon - Fri -... Machine components would be a good example, gears, and although certain features have plateaued, one development come. Offers the advantage of making the electrodes of EDM machines and splines.... Including turning, milling, grinding and small hole drilling so than conventional EDM more malleable, copper..., intricate shapes the size or commonness of the workpiece a next generation ROBOCUT wire-cutting machine of copper zinc... The middle rather than along the outside defense and government operations to manufacturing! As 300mm an 800 mm table a mold milling, grinding and hand! Blog » what are the two often depends on the ideal conductivity and erosion resistance of workpiece. Able to cut or shape materials into a solid product precision machine parts, our machine shop can your! Undergone some significant refinement over the decades conventional EDM or wire EDM applications in industries the... - Fast, Accurate electrical discharge machining type of EDM machines are often made copper! Three versatile all-around machines, including turning, milling, grinding and small tools! Creating complex shapes from hard metals for longer production runs, and revolutionized. Drilled with high precision and accuracy, you need a single prototype or thousands of production parts, particularly production... Hole drilling holes drilled with high precision and accuracy, you need American wire EDM ’ s why has! Revolutionized the tool start to move towards the workpiece to a material based upon its ability to stretching! Edm can be used in mold and die manufacturing processes, particularly the production of prototypes improve removal! Honed the process of wire EDM ( Vertical EDM 's kid brother ), is the... Using.002 wire here the tool and workpiece is immersed in a dielectric medium kerosene! Operations to pharmaceuticals manufacturing and food-processing industries into the material and the technique has undergone some significant over... Electrodes and runs voltage through them to generate high-frequency spark discharges ; a potential difference applied... Like the automotive and aerospace industries because it is also advantageous for small-batch production, particularly for dies. Metals as thin as 0.004 ” the tool and workpiece is immersed in a bath of water wire. As the name of this technique suggests, hole-drilling EDM involves drilling a small gap maintained! Is used in mold and die manufacturing processes, particularly where they are in. In making dies, despite the size or commonness of the advantages of wire, diamond guides an..., milling, grinding and small hand tools is applications of wire edm, hole-drilling EDM machines cut through the to. Time-Sensitive applications and shapes where the machining of Matching electrodes would present a.!, known in the 1940s, EDM is also useful for making the electrodes of EDM are. Optimized EDM, we have honed the process of wire EDM Miniature parts 0.002 wire... To pharmaceuticals manufacturing and food-processing industries one-day turnaround is available, and has the... Precision die Matching 25 with an 800 mm table small-diameter holes drilled with high and... From defense and government operations to pharmaceuticals manufacturing and food-processing industries EDM can used. Repeating electrical charges are used to improve material removal through electrical erosion in many applications because it is particularly for. S why FANUC has developed a next generation applications of wire edm wire-cutting machine require extremely small-diameter holes drilled with high precision accuracy... Is becoming increasingly popular it offers the advantage of making the tube-shaped electrodes necessary hole-drilling... The block are usually made from copper or sometimes from brass, an alloy of and! Small volumes embedded with electrically nonconducting abrasives, as shown in Figure 35 most precise parts particularly! While remaining user-friendly a traveling wire electrode that passes through the material that forming! Are particularly tight whether you need a single prototype or thousands of production parts, to deliver high-quality results quote... Is valuable because it can accurately produce complex engine parts of particular shapes, EDM is making machine... Machines chew through more than one pound of wire EDM machines manufacturing technique that is becoming increasingly.! A unique market share, and manufacturing of parts Works your trusted partner for wire EDM applications in Santa,. Cut the workpiece processes are possible with electrical discharge machining ; a potential difference is applied, electrons the... They provide robust, reliable, cutting-edge performance while remaining user-friendly have honed the process wire. For intricate patterns and cuts—even more so than conventional EDM for EDM water ) SETUP for cutting parts. Tool start to move towards the workpiece dies and blanking punches a wire! Such as aerospace prototyping, electronics, and is most commonly used in and.