The shortest and most descriptive answer to the question of what a wire EDM machine is is that it’s a machine that uses a wire to cut through a high current. Unlike traditional processes, these machines utilize technological manufacturing methods, enabling the machining of even hard or complex conductive parts with micron precision. So, what do wire EDM operators do? Wire EDM operators control the machines, which operate by generating high temperatures through electrical discharges when wire electrodes connected to different electrical poles are brought into contact with the part, resulting in metal melting and chip removal. The chip removal rate can vary depending on the amount of energy generated by each spark and the time interval. Wire EDM machines consist of two programmed stages. In the first stage of the program, the shape of the part is drawn on a coordinate plane, assigning circle and line numbers to each point on the shape. In the second stage, the actual shape is determined by cutting. Once the cutting process begins, the wire EDM cutting process is completed. The wire diameters used in these machines range from 0.05 to 0.4 mm. The materials used are brass, molybdenum, and tungsten wire electrodes. In wire EDM machines, the copper wire is positively charged, while the table is negatively charged. The cutting process occurs when the wire touches the workpiece. Wire EDM is used in many industrial applications for parts that are difficult to machine. Wire EDM machines, particularly used extensively in mold making, are also quite effective in the production of gears. This is because a part removed from a wire EDM machine does not require regrinding.
What Materials Can Be Processed Using Wire EDM Machining?
Wire EDM can be used with any conductive metal, including:
- Copper
- Carbide
- Tungsten
- Bronze
- Carbon steel
- Inconel
- Stainless steel
- Hastelloy
- Kovar
- Titanium
- Carbon graphite
- High alloy steel
