Wire EDM Cutting: What are the Pros and Cons?

09 October 2020

Numerous individuals take a gander at the subject of wire electrical discharge machining (EDM) cutting regarding how the technique piles facing laser cutting, 3D producing, or conventional machining for multi-pivot moulding of metal. What most people fail to consider is the importance of identifying its advantages and drawbacks to decide its usage. Below are the pros and cons of wire EDM cutting.

The Pros of Wire EDM Cutting

With the wire EDM cutting cycle, controlled and fast rehashed electrical charges are utilized to eliminate material from electrically conductive materials. It is an exact technique for the correct applications of little parts with tight resistances at high volumes. For instance, for large scale manufacturing of pins, tests, and other strong metal parts with breadths under 0.50 mm, wire EDM can convey: profoundly repeatable lengths without end damage, twisting, or delaminating and much better cost-adequacy than laser cutting.

For little distance across solids, wire EDM cutting likewise offers incredibly high proportions of focal inclination. For instance, EDM can cut a valuable metal wire of 0.004″ (0.1 mm) width to a length of 1″ (25 mm), while accomplishing a length resistance of ±0.001″, radiuses closes, and a Ppk well over the standard least of 1.33.

Wire EDM can cut breadths extending from a couple of thousandths of an inch to a few inches, to lengths from 0.5″ (12 mm) to 18.0″ (450 mm) and with high dimensional precision. Since it doesn’t include a wheel or saw teeth, the wire EDM cut methodology, for the most part, doesn’t leave any burrs, and the kerf width is normally 0.004″ to 0.012″ (0.1 to 0.3 mm).

Wire EDM cutting is also versatile in the hardness of the conductive metals it can cut without breaking a sweat, extending from copper to the hardest materials including molybdenum and tungsten. EDM likewise gives a characteristic range to the end cut; this might be a favourable position, contingent upon the application.

The Cons of Wire EDM Cutting

The most broadly realized negative is that wire EDM cutting is a moderate technique. Present-day EDM machines with AWT (programmed wire stringing) and CNC capacity can be modified to work “lights out,” to help alleviate the moderate cutting pace. In any case, for high volumes of parts with distances across bigger than 0.020″ (0.5 mm), a strategy, for example, meagre wheel rough-cutting may be liked.

Because of the idea of wire EDM cutting — eliminating material by utilizing quickly rehashing, controlled electrical charges along a strand of metal wire — the technique is restricted to electrically conductive materials. Therefore, any material that is a composite or covered with a dielectric isn’t achievable for EDM.

The absolute EDM condition — including the wire, deionized water, and workpiece — is charged. The wire’s rehashed electrical releases can warm the objective area of the workpiece to thousands of degrees. This can bring about thermal worry to neighbouring segments and cause some measure of waste. The wire itself likewise endures harm, so the EDM machine should constantly take care of new wire.

Contingent upon the metal being cut, another hindrance of wire EDM cutting is that an oxide layer can shape on the cut surface. This may require optional cleaning, which adds to cost. Wire EDM cutting is best for strong materials, so the technique is certifiably not a decent decision for the cut-off of tubing.


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