What Is a Wire Electrical Discharge Machining (EDM) Service?
Wire Electrical Discharge Machining (EDM) Service is a process where an electric current is passed through a very thin wire, which is then discharged to shape the surface of the metal being processed. This technique operates similarly to a saw, but with high precision.
EDM Service can process any conductive material, regardless of its hardness. Commonly used materials include iron, stainless steel, copper, aluminum, and brass. The wires used in EDM are extremely thin, ranging from 0.02 mm to 0.3 mm in diameter, enabling intricate and precise shaping that is challenging with conventional machining methods.
Uses of EDM Services
EDM Services are ideal for processing any shape of conductive materials with high precision. This method is especially useful in creating fine gears and ultra-precision press dies, where machining of diameters less than 0.05 mm is required. Unlike traditional machining which requires multiple steps, EDM Services can achieve complex and precise processing using only wires based on a programmed design.
Flow of EDM Services
EDM Services are conducted using a wire EDM machine that cuts the workpiece through an electrical discharge phenomenon between the workpiece and a continuously running ultra-fine wire electrode. The process involves:
- Setting the workpiece on the machine’s table and threading the wire through the starting hole.
- Initiating spark EDM Service when the wire, insulated in a pure water-filled tank, approaches the workpiece to within a few tens of microns.
- Generating high temperatures through pulsed current flow, melting the workpiece.
- Removing the melted metal through a steam explosion of pure water.
- Cooling the workpiece with water.
- Repeating the process hundreds of thousands of times per second to cut the workpiece.
- Moving the table (or wire) to cut according to pre-entered data, with the final product being separated from the workpiece when the machine returns to the starting point.
EDM Services are versatile and capable of processing various conductive materials and complex shapes. Unlike traditional cutting where the cutting edge wears down and must be harder than the workpiece, EDM uses relatively inexpensive materials like brass and tungsten. Since there is no direct contact with the workpiece, costs are reduced. However, EDM Services are less suited for mass production due to the slow processing speed from the heat generated during discharge.