Electrical Discharge Machining or EDM is a highly efficient and precise mold and die-cutting process. With the help of EDM, you can cut workpieces into any desired profile with an accuracy of up to 2 μm (microns). It can cut many hard materials and is one of the world’s most precise CNC cutting processes.
There are many types of EDM processes. One of the most commonly used EDM processes is Wire EDM. It provides nearly 100% precision for manufacturing tools and several other metal parts used for simple and typical machine applications.
Wire EDM is prevalent in the electronic, automobile, and aerospace industries when it comes to large-scale production. In this post, we will help you know more about the primary process, applications, pros, and cons of Wire EDM.
Basic wire EDM process
Wire EDM is a particular type of CNC machine, and its apparatus consists of a brass wire that’s continuously fed into a metal sheet or block that requires cutting. The workpiece and wire will be submerged in a dielectric fluid during the process, and this will cool down the workpiece and control the heat produced during the process. The cool down helps prevent uneven expansions inside the workpiece.
The cutting process is done via electrical discharge. The wire produces discharge but won’t be in actual contact with the workpiece. To start the cut, you must decide on a starting point. Suppose you’re cutting from a steel sheet. Generally, the cutting process starts from one corner of the workpiece material.
However, if you want to start cutting from somewhere in the middle, you must first drill a hole. You must use an electrode that continuously rotates inside the dielectric fluid supplied via a pressurized jet. Unlike traditional drilling methods, EDM electrodes drill holes much faster. Once you’re done with the hole, you can start the cutting process.
Advantages of wire EDM
A wire EDM machine is an effective tool used in die-cutting and taper cutting metal. Among its advantages includes efficiency when cutting super-hard metals, heavily thick blocks, and complex workpieces. New and used EDM machines are versatile tools that are also perfect for fabricating small workpieces that demand maximum precision with little to no damage.
There are two main advantages of Wire EDM. Firstly, it can machine complex workpieces that are difficult to achieve with conventional lathing or cutting processes. Second, it can efficiently cut hard metals and blocks with heavy thicknesses. Furthermore, it can handle minute machining, even on very small workpieces.
With the help of an EDM machine, you can make the smallest holes with maximum precision. You can also do taper cutting, so this process has numerous different advantages. In short, it’s a versatile cutting tool that allows you to perform precision cuts with minimal to no damage. However, wire EDM has got its fair share of disadvantages as well.
Disadvantages
The main disadvantage of the EDM process is that it’s typically hard to find the right talent to work with. Like certain types of welding, EDM requires precision workmanship to be done right. Without it, you may end up with substandard results and financial losses.
For instance, you can easily overcut your workpiece without the right expertise, especially while trying to cut sharp edges. This can either happen due to a lack of caution or mechanical problems such as electrode wear, which need professional attention. Apart from these, EDM also consumes a lot of power, making it an expensive process.
To summarize
Wire EDM cutting has some unique applications, where you need high precision cutting and accuracy. With the help of wire EDM, it’s possible to machine parts with precision. However, it’s got its fair share of disadvantages as well. Nonetheless, Wire EDM can ensure quality manufacturing with the right expertise.
