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Electrical discharge wire cutting (wire-walking) is an electrothermal production process that uses electrical discharge to remove material from the workpiece. It is an improvement on traditional EDM methods, is compatible with almost all conductive materials, and can be processed into complex designs and shapes. This article will discuss EDM, compatible materials and their applications in many industries.
Wire cutting is a non-contact reduction manufacturing process that uses charged fine wires and dielectric fluids to process metal parts into the desired shape.
Wire-cut discharge machining is a versatile precision machining process that can be used to manufacture complex shapes and geometrics. It is commonly used in the aerospace and medical industries where strict tolerances need to be met, and can also be used to manufacture hand plates or mass-produced parts.
With the expansion of industrial production scale and the development of manufacturing technology, wire cutting technology as a special processing technology, with its high processing precision, high production efficiency, low power consumption, low manufacturing cost characteristics, has been widely used in machining production. Especially in the mold processing industry, EDM technology is widely used in cold die and extrusion die processing, changing the past processing mode with separate die and curve grinding, shortening the manufacturing cycle, reducing manufacturing costs, and high precision.The process produces precise cuts by melting or vaporizing the material instead of removing it with a tool. Therefore, it can easily process parts features that are not suitable for traditional processing techniques. However, the parts must be electrically conductive.
2,Applications:
From hand plates to complete parts production processes, many industries use wire-cut discharge machining machines.
-auto industry
Parts in the automotive industry have complex shapes and high precision requirements. As a result, the industry tends to use wire-cut machine tools, a process suitable for opening holes and cavities to customize automotive parts.
-aerospace industry
Wire-cut machining has very small tolerances and is the preferred machining process for aerospace parts manufacturers. This process, like the water knife cutting process, is especially suitable for parts that cannot withstand the high temperatures and stresses generated by traditional cutting tools.
Parts in the aerospace industry require excellent surface finish and precision. Manufacturers have been using wire-cut processes for years to make engines, turbine blades, landing gear parts, and more.
-medical industry
Wire-cut electric discharge machining machines can process complex parts with high precision and are suitable for all medical fields. In addition, metals that work well with wire-cut discharge machining services are also often used in the manufacture of medical devices.
Because the diameter of the wire determines the size of the incision, wire-cut machines can add tiny features to parts such as dental implants and syringe parts without compromising their structural integrity.
3,Specifications
| material | |||||
| aluminium | Aluminum has excellent thermal and electrical conductivity. However, aluminum is naturally soft and may produce gelatinous buildup after processing. If not properly operated, it is difficult to cut during processing. | ||||
| titanium | Edm machining is well suited for titanium because the process can withstand the viscosity of this alloy and break down lengthy chips. However, deionized water is needed as a medium to help control the heat generated during processing. | ||||
| steel | Steel is a very strong metal, and many manufacturers tend to use wire cutting machines instead of CNC machines for machining complex steel features. However, this material generates a lot of heat, so necessary precautions need to be taken. | ||||
| brass | Brass has a high tensile strength and is easy to cut by machine. But the cutting speed should be slow because it is a soft metal. | ||||
-Cutting precision, basically no further processing of the workpiece;
-Suitable for processing small parts and cutting highly fine projects;
-It is suitable for manufacturing complex designs and shapes that are difficult to complete in traditional CNC machining.
-In just one processing stage, the machine can cut the material without leaving burrs or deformations;
-The process is continuous without interruption.
FAQ
-What other types of EDM are available?
In addition to Wire cutting discharge machining (Wire EDM), there are drilling discharge machining and sinking hole discharge machining. They differ in the electrodes they use. The electrode of drilling and discharging machining is tubular, which can process finer and deeper holes. Sink hole discharge machining, on the other hand, uses conductive metal to form a "positive electrode" of the desired shape.
-What is the difference between wire cutting and laser cutting?
Laser cutting uses a high-power thermal beam to cut the material, while wire-cut discharge machining uses the electrical processing of the workpiece of the wire.
-Why use deionized water in wire-cut discharge machining?
Deionized water has low carbon properties, which can be used as a coolant to regulate the dielectric temperature.