Fa… Wire-edm is, usually, slower than other methods. Wire EDM - Recommended Materials. Wire EDM Wire Cut Electrical Discharge Machining is a metal working process where electrical erosion is utilized to separate material from a conductive work piece. Electrical discharge machining, also known as spark machining, spark eroding, die sinking, wire burning or wire erosion, is a metal fabrication process whereby a desired shape is obtained by using electrical discharges. The movement of the guides and the workpiece are controlled via the CNC computer. With the wire EDM cutting process, controlled and rapidly repeating electrical charges are used to remove material from electrically conductive materials. In Wire Electrical Discharge Machining (WEDMing), or Wire-Cut EDM, a thin single-strand metal wire is fed through the work piece, typically occurring while in a submerged tank of dielectric fluid or deionized water. A low melting/vaporization temperature of the wire will prove the best for flushability. Wire EDM Capabilities. In Wire EDM cutting, the material to be cut is submerged in a dielectric cutting fluid, usually deionized water. For example, for mass production of pins, probes, and other small, solid metal parts with diameters under 0.020” (0.50 mm), wire EDM can deliver: 1. Except in older machines that specify the use of copper wire, this wire is seldom recommended. It is also used when the final piece needs to have low stress, Wire EDM has low cutting force for material removal and little change in the mechanical properties is usually seen. When using longer on times (roughing), melting will occur. This wire consists of a thin (approximately 5 micron) zinc coating over a core which is one of the standard EDM brass alloys. Undergoing annealing in a special furnace diffuses the pure zinc coating into a mixture of nearly 50% brass and 50% zinc (actually, zinc content is approximately 45-47%), which is higher than the 40% threshold which was the previous manufacturing limitation. If the smallest diameter wire is used then the cut can be within plus or minus a micrometer. This allows it to cut very fine, very straight-walled details with sharp definition. Wires with high zinc content make a better EDM electrode but EDM wire with zinc percentages approaching 40% are difficult to produce, so a special method of producing wire with a higher zinc surface has been devised. Brass wires with a dull, matte finish or with spots or discoloration are indications of oxidation or contamination. If no, wire it. V W Broaching works with a variety of materials for wire EDM machining. Part Prototypes. The EDM wire cutting machining services process utilizes an electrical current discharge between two electrodes, which are the tool and the workpiece. In these machines, this wire must be used to wire-cut all materials simply because there is no other alternative. Innovative machining technologies such as wire cut – also know as wire erosion or wire EDM, become ever more in demand, especially as wire cut machining automation and accuracy improves to new levels of performance. Like all machining processes, EDM requires a balancing act between speed and surface finish. Many machines … Contact us today for a quote on your high quality, precision manufacturing need. Consequently, moly and tungsten wires, with high melt/vaporization temperatures cut slowly and flush poorly, but are satisfactory for skim cuts where speed is not an issue but part straightness and crisp geometry is. In special cases, typically in medical and military applications, there can be no copper or zinc contamination of the wirecut surface. However, there are two wires being produced with a 60/40 Cu/Zn content for faster cutting speeds. Brass wires are usually a shiny brass color. These wires are suited for fast cutting of tall workpieces, volume production and in poor flushing conditions. Because of it’s high working temperatures, the EDM craters left on the wire’s surface are very small compared to those left on a brass-based wire and therefore will not flush as efficiently. Wire-cutting EDM is commonly used when low residual stresses are desired, because it does not require high cutting forces for removal of material and there is no direct contact between the work piece and wire eliminating the mechanical stresses during machining. Coated EDM wires are wires that have had a very thin layer (2-3μm) of pure zinc applied to a brass or copper core. Modern Wire EDM machines often include multiple heads to cut more than one piece and automatic wire threading. Excep… Typically the electrode diameters range from.004″ –.012″ (.10mm –.30mm), … Wire EDM Cutting method in which an electrically charged wire is fed through a workpiece creating an electric discharge that cuts a contour in its horizontal plane. Cutting. Obversely, wires with high elongation can taper-cut to 45° but with much reduced threading relaibility. A thin single-strand wire electrode is placed over the material on a CNC-controlled robotic guidance system. There are various wire EDM machines for sale in different sizes to suit customers’ needs. We want the wire surface to vaporize, to quickly turn into gasses, instead of contaminating the gap with resolidified “chips”. Virtually any conductive material can be cut using Wire EDM. However, manufacturing difficulties arise when the volume of zinc approaches 40% and its crystalline structure changes to a gamma phase, causing the wire to become very brittle and difficult to draw. Wires with low percentages of elongation will thread reliably but are limited in tapering ability. MWI offers a full compliment of metallic electrode materials and sizes. The combination of break-resistance with the performance of 50/50 brass can make this wire a problem solver for difficult applications. The advantage of EDM is that it can cut hardened materials and exotic alloys while also providing excellent surface finishes as a bonus. Tensile strength is the maximum load-bearing capability given to a material based upon its ability to resist stretching and breaking. An electric current is run through the wire, creating an electrical spark of intense heat (8000-12000°C). Wire EDM services are typically used to cut hard metals that are sometimes difficult to manipulate using other cutting methods. The wire is used as it can be continuously spooled so that the electrode does not become too eroded. Wire Electrical Discharge Machining Traveling Workpiece Wire Electrode Motions Wire Motions Wire EDM Used Primarily for Through Hole Machining. Since higher conductivity is more efficient, increased cutting speeds are the usual results. The wire is usually made of a single strand of brass, and is held at the top and bottom by diamond guides, the guides can move in the x-y plane and the upper guide can move independently in three axes. As the spark jumps across the gap, material is removed from both the workpiece & the electrode. Economical cutting of tool steels and most metals is possible with plain brass wire. All chips have mass and therefore, will “take up room”. In EDM, the higher the conductivity of the wire, the more power can be delivered to the workpiece. There is usually a low conductive liquid medium between the two, such as deionized water, which is continually flushed as the work progresses. Much like the carpenter’s fretsaw, wire EDM can cut in all directions. Most wire EDM machines hold the wire vertically and move the workpiece in x and y. Hot-dipping is another method of coating the wire. Wire EDM (electrical discharge machining) is an accurate and effective method of producing custom parts and components from metal. Standard wire machines use a continuous piece of brass wire to cut hard materials. The term hardness is often mistaken for tensile strength. It is determined by the maximum load in pounds per square inch divided by the cross-sectional area of the wire. High-tensile wire is also good for skim cuts, aiding in part straightness and geometric accuracy. Below are listed the more common types of materials we machine using Wire EDM: Inconel : Aluminum: Vasconal 300: Tool Steels: Aluminum … Wire EDM machining (also known as \"spark EDM\") works by creating an electrical discharge between the wire or electrode, & the workpiece. Wire cut electrical discharge machining (WEDM), is used to cut hardened metal plates as thick as 300 mm that are typically difficult to machine in any other way. Wire EDM is a method to cut conductive materials with a thin electrode, a wire.There is no physical contact between the part that is being machined and the wire. The hardness of the material is not a factor. Diffusion-annealed wires are available in tensile strengths from 62,000-128,000psi and appear yellowbrown to brown in color. The dielectric fluid in this case—usually deionized water—is flushed through the cut as it proceeds, again serving to carry off particles and control the sparks. Because of its high tensile strength, moly wire aids in maintaining excellent wall straightness and reducing the number of wire-breaks common with many small and fine brass wires. Sabre Cut SC-1; EDM Metallics. Today, there are more electrode choices for wire EDM than there are for sinkers. One of the electrodes is called the tool-electrode, or simply the tool or electrode, while the Wire cut EDM (or WCEDM) discharges the electrified current by means of a taut thin wire, which acts as the cathode and is guided alongside the desired cutting path, or kerf. The first wire used for wire EDM was copper. Although this wire is very expensive, cuts poorly and is hard to work with, it is sometimes the only solution to an EDM problem. This is a very high strength wire with tensile strength in excess of 275,000psi. Zinc coated Brass wire was one of the first attempts to present more Zinc to the wire’s cutting surface. There is no true index or “rating” of fracture resistance, so fracture resistance of an EDM wire might better be described as wire toughness or resilience. Properties. EDM (electrical discharge machining) is a non traditional metal machining process that uses spark erosion to remove material from the workpiece. Why choose graphite for EDM applications? For cutting of different types of metal wires, the rendered CNC wire cut EDM machine is used. The spark gap is small enough already and we don’t need “chunks of stuff” floating around in it. All Rights Reserved. 2. In addition to metals, other conductive materials such as graphite, diamond and metal alloys can be machined using wire cut EDM. In the machining area, each discharge creates a crater in the workpiece (material removal) and an impact on the tool (wear of the tool/electrode). Zinc coated wires will cut much faster and break less often than plain brass wires and are recommended for fast roughing and finishing of steels. This criteria eliminates all copper-family wires and forces the use of a moly or tungsten wire. High-tensile EDM wire provides better edge straightness and so is a good choice for single-pass parts and in small- and fine-diameter wires to reduce wire breakage. Wire EDM is referred to in many ways: wire cutting, wire burning, and traveling wire EDM. This would include all metals, including steel, aluminum, brass, titanium, and alloys and super alloys of all types. mechanical stresses during machining. Even though melting produces chips, lowtemp electrode alloys (zinc-coated) will produce larger craters on the wire surface to carry more water and contaminants away from the gap, aiding flushing. The hardness or temper of a wire refers to the wire’s ductility, or its ability to undergo elongation. In this short study, we will first examine the different properties of EDM wire, then we will briefly examine the different types of wires and their applications. Hard wire works better than soft wire in EDM machines with automatic wire threading. We have economy and utility-grade wires, wires for speed, wires for carbide and PCD’s, wires for tapering, and fine-wire machining. Brass wires for EDM are typically an alloy between 63/37 (American and European) to 65/35 (Asian), Cu/Zn ratio. Larger diameters (.006”-.012”) have tensile strengths in the range of 116,000-145,000psi. You must have JavaScript enabled in your browser to utilize the functionality of this website. Brass wires are a good, all-around utility wire that can be used by most modern machines. Owing to our industrial experience and knowledge of this domain, we manufacture the premium quality of CNC Wire Cut EDM Machine. Pure zinc coatings will have a shiny, silver color while a zinc-oxide coating will appear dull gray. Electro-galvanization is the most precise method of application, depositing pure zinc, atom by atom onto the body of the wire, insuring uniform thickness and surface uniformity. Wire cut EDM is a specific kind of EDM process and is one of the most common. Available in small diameters (.001”-.002”), tungsten wire has the highest tensile strength of all EDM wires. Complex shapes that would otherwise be difficult to produce with conventional cutting tools, Extremely hard material to very close tolerances. All conductive materials can be discharged . All prices shown on this website exclude VAT. Tensile strengths of brass wires range from 54,000-173,000psi, depending upon the composition of the alloy and it’s temper. On closed-guide machines, a hard wire will thread better than a softer wire, but a soft wire will taper-cut better. Among the industries that make use of components manufactured by EDM include the semiconductor industry, medical and instrumentation. 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