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WireCutting Technology

December 22,2017.

EDM Wire Cutting Machine (Wire electrical Discharge machining wedm), is a category of electrical processing, is the former Soviet Union la Zalinko Couples study switch contacts by spark discharge corrosion damage phenomenon and cause, found that the instantaneous high temperature spark can make local metal melting, is oxidized and corroded, thereby creating and inventing a method of EDM.

The basic EDM process is really quite simple. An electrical spark is created between an electrode and a work piece. The spark is visible evidence of the flow of electricity. This electric spark produces intense heat with temperatures reaching 8000 to 12000 degrees Celsius, melting almost anything. The spark is very carefully controlled and localized so that it only affects the surface of the material. The EDM process usually does not affect the heat treat below the surface. With wire EDM the spark always takes place in the dielectric of deionized water. The conductivity of the water is carefully controlled making an excellent environment for the EDM process. The water acts as a coolant and flushes away the eroded metal particles.

Wire Cutting

EDM wire cutting uses a metallic wire to cut a programmed contour in a workpiece. Extrusion dies and blanking punches are very often machined by wire cutting. Cutting is always through the entire workpiece. To start machining it is first necessary to drill a hole in the workpiece or start from the edge. On the machining area, each discharge creates a crater in the workpiece and an impact on the tool. The wire can be inclined, thus making it possible to make parts with taper or with different profiles at the top and bottom. There is never any mechanical contact between the electrode and workpiece. The wire is usually made of brass or stratified copper, and is between 0.1 and 0.3 mm diameter.


Depending on the accuracy and surface finish needed, a part will either be one cut or it will be roughed and skimmed. On a one cut the wire ideally passes through a solid part and drops a slug or scrap piece when it is done. This will give adequate accuracy for some jobs such as CNC machining parts, but most of the time, skimming is necessary. A skim cut is where the wire is passed back over the roughed surface again with a lower power setting and low pressure flush. There can be from one to nine skim passes depending on the accuracy and surface finish required. Usually there are just two skim passes. A skim pass can remove as much as 0.002" of material or as little as 0.0001",which will at most reach to CNC machine’s precision.


EDM Wire Cutting Classification


Distinguish fast-moving wire cutting, in-line cutting, walking wire cutting. 1: fast-moving wire EDM wire cutting speed for 6~12 mm, electrode wire for high-speed round-trip movement, cutting accuracy is poor. 2: In-line wedm is a fast-moving wire cutting on the basis of the realization of frequency conversion multiple cutting function, is a new process of development in recent years. 3: Walking wire EDM wire cutting speed for 0.2mm/s, electrode wire to do low-speed one-way movement, cutting precision is high for CNC machined part.


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