MP 3 Edm

Wire EDM:[1]
Wire electrical discharge machining is a non-contact subtractive manufacturing process that uses
an electrically charged thin wire with a dielectric fluid to cut a metal part into different shapes. The
process produces small chips and precise cut lines by melting or vaporizing the material rather than
cutting it. As a result, it can conveniently machine parts unsuitable for conventional machining
techniques. However, the parts must be electrically conductive.
Working mechanisms of Wire EDM: [1]

EDM wire cut process The wire-cut EDM process has a simple mechanism. Machining a part
using the process involves submerging the workpiece into a dielectric fluid, securing it with a machinist
vise, and running the wire through it to produce sparks as it passes an electric current.
In other words, the wire carries one side of the charge, and the workpiece, which must be a
conductive material, carries the other side of the charge. When the two get close, a hot electric charge
jumps the gap and melts tiny pieces of the metal away.
The electric spark is the cutting tool to cut the material in the desired shape. Additionally, the
wire EDM process involves deionized water to control the process and flush away tiny particles removed.
Components Wire EDM Machine :[1]

The machine comprises several parts that work together to give a material the desired shape. Below
are the components of the machine.
1. CNC Tools
2. Power Supply
3. Wire
4. Dielectric Medium
5. Electrodes
CNC Tools
The CNC tools control the entire operation of the Wire EDM machining process. Controlling the
entire operations include being in control of the sequencing of the wire path and being able to manage the
cutting process automatically.
Power Supply
The power supply unit is the component that delivers pulses (from 100V to 300V) to the wire
electrode and the workpiece. Furthermore, it controls the frequency and strength of the electrical charges
that pass through the wire electrode to interact with the workpiece. It is necessary to use a highly
developed power supply unit to deliver the necessary quality and type of charges during Wire EDM
machining.
Wire
The wire serves as the electrode to create the electrical discharge. The shape and thickness of the
workpiece directly influence the wire’s diameter. Typically, one can use wires with diameters ranging
from 0.05 to 0.25mm.
Common types of wire used for EDM.
Brass Wire:
Brass is the most common EDM wire material because of its excellent conductive
properties. It is an alloy of copper and zinc, and the higher the zinc content, the faster the wire
cuts. However, there should be a balance because when the zinc content is over 40%, this
decreases the corrosion rate of the brass wire.
Zinc coated Wires
As the name implies, you obtain it by applying a coating of pure zinc or zinc oxide on the
wire surface. Manufacturers use zinc-coated wires because it improves the machining speed.
Diffusion-annealed Wires
The diffusion annealing process helps to create wires with higher zinc content (more than
40% zinc). It involves coating wires with layers of pure zinc. These wires are ideal for mass
production and can machine many materials.
Dielectric Medium
The wire-cut EDM process must be carried out in a tank filled with dielectric fluid. This liquid
prevents the tiny particles from the workpiece from getting attached to the wire electrode. The most
common medium is deionized water which cools the process and gives the workpiece a good surface
finish.
Electrodes
The electrodes in the machine are the wire (cathode) and the workpiece (anode). The servo motor
controls the wire electrode, ensuring it does not come in contact with the workpiece at any point during
the wire EDM cutting process.
Advantages of EDM[2]
(Part Geometry )
1. Thin walls are possible.
2. Cut internal corners with very small radii.
3. Cut thin slots in extrusion dies with wire EDM.
4. Produce blind and high aspect ratio pockets with sinking EDM.
5. Produce non-round openings and cavities.
6. An alternative to broaching for 2D shapes like gears.
(Cost Advantages of EDM)
1. No special tooling (saves money and lead time.) Skimming passes eliminate secondary finishing
operations.
2. Laminate layers of material to cut multiple parts simultaneously.
3. Enables reuse of cut out slugs rather than producing chips.
4. Avoids moving a part through multiple conventional processes.
5. The final shape is achieved in a single set up (which also improves accuracy.)
(Other advantages of EDM)
1. EDM can create surface finishes as smooth as 5 RMS or around 4 micro-inches
2. Material hardness has little effect on EDM wire cutting rate and doesn’t limit possible part
geometries. Tungsten carbide, tool steel, Inconel and any metal harder than RC38 are all good
candidates where conventional machining is slow and expensive
Limiattions of EDM:[2]
1. EDM requires an electrically conductive workpiece. It will not work on wood, plastics or
composites.
2. Material removal rates (MMR) are usually lower than for conventional processes.
Applications Of Wire Electrical Discharge Machining:[1]
Many industries use wire EDM machines from prototyping to complete production runs. Below
are some industries.
Automotive Industry
The parts in the automotive industry come in complex shapes and sizes and are mostly hard. As a
result, the industry favors using wire EDM machines because the process does not rely on mechanical
forces, and the wire electrode does not need to be stronger than the workpiece. The process applies to
making holes and cavities to customize automotive car parts like bumpers, dashboards, car doors, and
many more.
WEDM medical applications
Medical Industry Wire EDM machines produce complex parts with a high level of accuracy for
use in all medical fields, including optometry and dentistry. Also, metals that work well with wire EDM
services are frequently used to manufacture medical equipment. Since the wire’s diameter determines the
cut’s size, the wire EDM machine adds tiny features to parts like dental implants and syringe components
without endangering their structural integrity.
Aerospace Industry
Wire EDM cutting produces parts with tight tolerances and is the go-to machining process for
aerospace part manufacturers. This process, alongside the waterjet cutting process, is especially used for
parts that cannot withstand the high temperature and stress associated with traditional cutting tools. Parts
in the aerospace industry need to have an excellent surface finish and be precise and accurate.
Manufacturers use the wire EDM process for years to make engines, turbine blades, landing gear parts,
and many more.
Conclusion
Wire EDM is a versatile and precise machining process that can be used to create complex shapes
and geometries. It is often used in the aerospace and medical industries, where parts need to meet tight
tolerances. Wire EDM can also be used to create prototypes or one-off parts. In this article, we hope that
you now have a better understanding of wire EDM.
Refrences:
1. https://waykenrm.com/blogs/wire-edm-process/
2. https://fathommfg.com/advantages-of-edm

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Wire EDM:[1]

Working mechanisms of Wire EDM: [1]

Components Wire EDM Machine :[1]

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