Wire EDM cutting

Wire EDM, also known as Wire Electrical Discharge Machining, is an electrical discharge machining technique that allows for precise cutting of metals and conductive materials using a thin wire. The process is mainly used in the precision industry, tool manufacturing, and injection molding.

Urządzenie

Electrical Discharge Machine GF Agie Charmilles_CUT E 600

Axis movements
X, Y, Z axes	600 x 400 x 350mm
U, V shifts	± 50mm
Angle of inclination of the wire height	30°/56 °/mm

Detail and electrode
Detail dimensions (W x D x H)	1030 x 800 x 345mm
Max. workpiece weight	1000kg

Wire rewinding system
Available wire diameters (Standard)	0.15 – 0.30mm
Permissible weights and types of spool (ISO standard)	8, 25kg

How does wire EDM cutting work?

Cutting is achieved by a series of electrical discharges between the wire and the material being processed. The wire, made of copper, brass or other conductive metals, moves at high speed and does not directly touch the material. As a result of the discharges between the wire and the material, a high temperature is generated, which causes the processed surface to melt and vaporize.

Key elements of the process

Wire: Typically 0.05mm to 0.35mm thick.
Dielectric Fluid: Typically deionized water, which removes heat and washes away the byproducts of the process.
Precision: This process allows for tolerances in the micron range.
Geometry: Allows for cutting very complex shapes in difficult-to-cut materials.

Advantages of Wire EDM Cutting

High precision: Wire EDM allows for extremely accurate shapes with tolerances as low as 0.001 mm.
No mechanical forces: Because the process is performed without direct contact between the tool and the material, there is no deformation or mechanical stress.
Can be used for hard materials: This technique is suitable for difficult-to-cut materials such as tool steel, carbides, titanium alloys and hardened metals.
Intricate shapes: Wire EDM allows for very complex geometries, sharp angles, narrow gaps and intricate patterns.
No thickness limits: Wire can cut through very thick materials, up to 300-400 mm, without losing precision.
Low thermal impact: Although the process uses high temperatures, the heat is not transferred to a large part of the material, which minimizes the risk of deformation.

Applications

Wire EDM cutting is used in many industries:

Toolmaking: Manufacturing injection molds, punches, and dies.
Aerospace: Machining hard titanium alloys and composite materials.
Medical: Manufacturing precision components for medical devices, such as implants.
Electronics manufacturing: Creating small, precise electronic components.

Summary

Wire EDM is an advanced machining method that offers exceptional precision and the ability to machine difficult materials. Although the process has its limitations, particularly in terms of speed and cost, its ability to produce complex shapes and cut hard materials makes it indispensable in many precision industries.