What Is a Wire EDM Machine?
Wire EDM machines are innovative machines that enable precision metalworking.
Electricity is passed through an extremely thin wire, melting conductive workpieces as it performs EDM processing. Wire EDM machines are also called wire EDMs.
A wide range of materials can be processed as long as they are conductive, but the processing method is limited to penetration only. It is also important to note that the melted part by heat becomes an altered layer, which changes the properties of the material.
With their high precision, wire EDM machines can process extremely complex shapes, and are used in a wide range of fields such as automobiles, aircraft parts, and electronic devices. They also make it possible to process parts that were difficult to process with conventional cutting methods, contributing greatly to improved efficiency in product development and research and development.
Applications of Wire EDM Machines
Wire EDM machines are used in a wide range of applications. They are used in fields such as molds, gears, and jigs, where advanced technology is required. Wire EDM machines and conductive materials can be used for a wide range of applications, from thin sheet metals such as steel, stainless steel, aluminum, and brass, to thin materials that are difficult to process, and even hard metals such as carbide materials.
In addition, since non-contact machining is performed using a wire electrode, the electrode is discharged without touching the workpiece, which has the advantage that even metals that are difficult to process by cutting can be easily machined. It is utilized in a variety of fields, including the manufacture of automobile and aircraft parts and precision equipment. They also make it possible to process parts and delicate shapes that were difficult to process with conventional cutting methods, contributing to improved efficiency in product development and research and development.
Principles of Wire EDM Machines
Wire EDM machines are characterized by their ability to perform high-precision metalworking in a non-contact, automatic operation. To start machining, a hole is first drilled in the workpiece and a wire is threaded through it, after which the workpiece is moved in a plane in the XY direction and cut according to NC data input in advance.
When cutting, a derivative liquid called processing fluid is used. Water and oil are mainly used, but water is increasingly being used because it is easy to handle, does not cause fires, can be left running at night, removes machining dust, and cools heat.
Two types of machines use water as the processing fluid: the spraying method (pouring method) and the penetrating method (dobbing method). The penetration method is the most common because it allows stable processing without interruption of water.
Types of Wire EDM Machines
There are five main types of wire EDM machines: manual wire EDMs, NC wire EDM machines, CNC wire EDM machines, submerged wire EDM machines, and flash-cut EDM machines.
1. Manual Wire EDMs
Manual wire EDMs are manually operated machines. They are mainly suited for processing simple shapes and small-lot production. Because of their low initial investment and simple operation, they are often used in small factories and research facilities.
2. NC EDM Machines
NC Wire Cutting EDMs are numerically controlled (NC) machines that perform machining automatically. They are used in medium to large-scale production lines because of their ability to process complex shapes and precision machining and their high productivity.
3. CNC Wire EDM Machines
CNC wire EDM machines are the most common type of machine where the machining is done by computer numerical control (CNC). They are highly programmable and can easily process complex shapes and a wide variety of materials. They are widely used in many fields, including the manufacture of automobile and aircraft parts.
4. Submerged Wire EDM Machines
Submerged wire EDM machines are a type of machine that performs machining while impregnated with a processing fluid. They are mainstream machines because they enable stable EDM without interruption of the processing fluid and provide high accuracy and quality of the finished product.
5. Flash-Cut EDM machine
Flash-cut EDM is a type of machine that enables high-speed and short-time machining. Compared to conventional EDM, machining time is greatly reduced, thus improving production efficiency.
However, there are some restrictions on machining accuracy and quality of the finished product, so the choice must be made according to the application.