What is Wire EDM?

Wire EDM (electrical discharge machining) is a process that removes material from a workpiece to create precise shapes and features. In wire EDM, a thin wire made of brass, copper, or other conductive material is strung between two spools and suspended over the workpiece. The wire is then lowered into the workpiece, and a series of electrical sparks are discharged between the wire and the workpiece to remove small amounts of material.

Wire EDM is typically used to machine hard materials, such as stainless steel and titanium, that are difficult to machine using traditional methods. It is also used to produce complex shapes and contours, as well as small, precise parts with tight tolerances. Wire EDM is widely used in a variety of industries, including aerospace, automotive, medical, and more.

How Wire EDM Works

Wire Electrical Discharge Machining is a precision machining process that utilizes electrical discharges to remove material from a workpiece. In this method, a thin, electrically conductive wire, usually made of materials like brass, is fed through the workpiece submerged in deionized water. The wire acts as the tool electrode, and a spark discharge occurs between the wire and the workpiece, creating intense heat, reaching temperatures of thousands of degrees Celsius. This heat causes a small portion of the workpiece to melt and vaporize, while the dielectric water surrounding the wire prevents electrical discharge from occurring elsewhere. The molten material is scattered into the dielectric fluid, leaving a small crater in the workpiece. The process repeats rapidly, with the wire constantly advancing, allowing for precise material removal. As the wire erodes during the process, fresh wire is fed from a spool, and the machine continually manages wire threading, ensuring a continuous, precise cutting action.

Wire EDM is ideal for cutting intricate shapes and fine features, with the ability to produce sharp inside corners and narrow slots without any contact, leading to a burr-free finish. The process's precise control and adaptability, coupled with the use of different wire materials and machine settings, make it suitable for a wide range of applications, including aerospace, medical devices, tooling, and more. This method allows for intricate, high-precision machining without the need for direct mechanical force, making it a valuable tool in the manufacturing industry.

De-Ionized Water: Wire EDM Cutting Medium

Pressurized and de-ionized water, or any dielectric fluid, provides resistance to the spark. This resistance helps to precisely control the level of voltage jumping from the wire to the workpiece, providing a consistent cut.

Unfiltered water does not work for this purpose. The minerals present in normal water act as a conductor of electricity which would mean uncontrollable cutting at lower levels of voltage. Resin tanks filter out the minerals, producing pure de-ionized water, which does not conduct electricity under normal circumstances. Only after enough voltage is applied will dielectric fluid ionize to conduct a current.

Dielectric water also serves to flush any shed material from the environment, ensuring a clean cut.

Wire EDM Applications

Wire EDM is a versatile and precise manufacturing process used across a spectrum of industries. Its ability to cut intricate shapes in a wide range of materials with exceptional precision makes it an invaluable tool for creating essential components. Below, we highlight some of the key industries and the common components Wire EDM is employed to produce in each.

In aerospace, Wire EDM produces turbine blades, engine parts, and structural elements, ensuring components that endure aviation's rigorous requirements. Military satellites rely on Wire EDM for satellite antennas, connectors, and complex parts, essential for national defense and security. The medical field benefits from Wire EDM for crafting dental implants, surgical instruments, and tiny, life-saving device components with exceptional precision. Optical equipment, such as lenses and mounts, relies on Wire EDM for fine and accurate cuts, ensuring components meet exacting specifications and provide reliable performance.

Tool and die components are shaped with Wire EDM, playing a vital role in manufacturing processes across various industries. In the pharmaceutical sector, it manufactures tablet punches, molds, and precision components, meeting strict industry requirements. Food manufacturing benefits from Wire EDM, creating precision parts for machinery and food production equipment, and maintaining high quality and safety standards. In the oil and gas industry, Wire EDM is indispensable for producing components that can withstand extreme conditions.

Wire EDM's accuracy and versatility make it essential in these diverse industries, supporting technology advancement and reliability with a wide range of precision components.

Owens Industries Wire EDM Materials

Today’s technology is advancing by leaps and bounds, requiring the CNC industry to advance right alongside it. Manufacturers producing extremely precise devices like implants, and surgical components of micron sizes or with intricate details choose wire EDM to get the job done right. Capable of cutting a multitude of materials – including titanium, stainless steel, copper, aluminum, Inconel, Kovar, carbide, and more – wire EDM is preferred over other machining techniques for its ability to quickly produce components with repeatable accuracy and measurable results.

If you’re looking for a machine shop offering wire EDM, before wasting money and time, make sure they can meet your needs. The proper equipment is important but qualified, experienced CNC programmers and engineers are a must when working on delicate medical products. If you’re looking for high-quality precision parts from a CNC shop you can trust, make sure to give Owens Industries a call. We’ve been providing ultra-precision CNC machining for over 70 years, and are dedicated to offering our clients the absolute best in Wire EDM.