Some are obvious, such as degree of metal removal and electrode wear, while others are much more subtle. If you need to do die tryouts on a form die, you can actually cut the sheet metal blanks to test the form die.”. Our company receives much work Copyright © 2020 EDM Club. From an operating standpoint, the more efficient Wire EDM machines will have a per-hour operating cost of around $4.00. It acts as a cathode in the process, generally cutting completely through the material. EDM can be used to machine difficult geometries in small batches or even on job-shop basis. WEDM Dielectric Basics P rior to plunging into the details of deionizing resin and regeneration, let’s first examine the role of the deionized water dielectric in a Wire EDM. Obviously, any workpiece that’s going to be machined with EDM has to be electrically conductive, but there’s more to the material limitations of electrical discharge machining than that. Control of the wire’s movement in an XY plane on modern-day machines is similar to other CNC-driven technologies. All newer machines operate fully submerged under a filtered water dielectric fluid, and high-pressure flushing is used to remove debris from the spark gap area. Wire Kerf The wire never contacts the workpiece. Similarly, there’s typically more than one way to cut parts. Work material to be machined by EDM has to be electrically conductive. “Workholding and the required machine setup time are often a bottleneck for many shops. 2. “There’s no cutting pressure, so if you’re working with little tiny pieces, you don’t need much of a fixture to hold them,” said Langenhorst. Harding, an electrical engineer, proposed using sparks to erode them away. The process of automating one or more EDM machines is similar to that of other conventional machine tools. Requirement: Course "V5 basics for NC Programmers" or Course "V5 Basis Block I" Content: Programming of contour operations on both 2D contours (wireframe and Sketch) as well as 3D contours (wireframe, Redge, Rsur) Programming on FAST4AXES Design Feature, a ruled surface, generated between an 3D upper and lower contour; Definition of conical, pocketing – and … That’s why most people pair a graphite mill along with a couple of sinkers; generally one mill can keep up with two or three sinkers.”, Regarding wire EDM, Pfluger noted that the machines call for considerably more maintenance and upkeep than a milling machine. The Basics to Wire Erosion EDM (Electro Discharge Machining) Wire Erosion is a precision engineering process where a work piece is cut through with a strand of wire, it creates electrical sparks between the wire and the work piece, and these electrical sparks cut the work piece. Due to the constant and continual renewal of the wire electrode, achieved level of precision is maintained. Machines are capable of cutting and re-threading the wire automatically, which greatly extends unattended machining time. The consumed wire spools are purchased on pre-wound reels that can vary in capacity, but 11- and 22-pound spools are the most common. These processing values are strictly for general expectations and guidelines, and can vary by application and by machine. ), EDM accessories and consumables (Image courtesy of MC Machinery.). Normal electrode sizes can range from under 1.0” square to 6.0” square, but can be larger. Wire EDM, which may also be called wire-cut EDM, is a relatively new technology first developed in the 1960s for NC (Numerically Controlled) machines. The wire is only used once because the discharge machining process erodes and reduces the size and shape of the wire. Choosing the right dielectric fluid for your EDM application is not always as straightforward as it might seem. The 2.5 Axis and 4 Axis cutting operations automate the creation of rough, skim and tab cuts. As workpiece materials become harder to machine by conventional methods or the detail size becomes small with higher L:D (length to diameter) ratios, Wire EDM becomes a more attractive method of machining. See Figure 1:1. A 1-pass process typically achieves a tolerance of ±0.001 (±0.025mm) and a surface roughness of 120µinRa (3.0µmRa), a 2-pass process achieves tolerances of ±0.0005” (±0.012mm) and a surface roughness of 70µinRa (1.8µmRa), and a 3-pass process achieves tolerances of ±0.0002” (±0.005mm) and a surface roughness of 25µinRa (0.6µmRa). (Image courtesy of, Basic machine components for a wire EDM. The amount and type of required machine maintenance and consumable wear items can vary greatly between the different Wire EDM OEMs and should be an evaluation factor when looking at new equipment. The most popular machine size provide a 14” x 10” X/Y stroke with an 8”~10” Z-stroke capacity, and support part weights in the range of 1,000~1,500 lbs. Today, wire EDM competes seriously with such conventional machining as milling, broaching, grinding, and short-run stamping. NC programmers for wire EDM. Hole popper EDM can also be used to create the pilot hole necessary for wire threading. Following the Wire EDM’s recommend maintenance intervals ensures reliable operation and prevents the loss of productive unattended machining. So, if you’re wondering whether EDM is the best bet for your particular application, the answer is always the same: it depends on your application. These tiny, hollow spheroids are composed of material from both the electrode as well as the workpiece. Moreover, while EDM is technically a stress-free machining process—since no direct mechanical force is applied to the workpiece), it’s still a thermal process and so has the potential to alter the metallurgy of the workpiece via heat affected zones (HAZs), recasts and micro-cracking. Wire EDM had its founding and initial use in the 1970s in die/mold applications; machining details such as dies, punches, inserts, etc. Process Fig. But the experts agree that more customers are inquiring about ways to automate the process. “The fundamental difference is that wire EDM maintenance MUST be performed as a proactive and preventative measure,” he said. Many sparks can … There is a hidden recycling bonus at the end to where the spent brass wire can be sold to a local scrap metal recycler. Some machines can also utilize CMM-style probe systems to find start locations and for 3D part leveling. Wire EDM revolutionized this industry in how these tooling components were made, as prior to Wire EDM, many complex hardened tool steel components required very time consuming and difficult segmenting and grinding to be made. We will be examining the three basic EDM processes: wire EDM, ram EDM, and small hole EDM drilling. EDM 6 EDM–Wire Basic Training 7 Maximize performance training EDM 8 EDM–Wire Advanced training 9 EDM–Wire Thin wires 10 EDM–Wire Advanced programming 11 EDM–Wire aperT -Expert 12 Dedicated training 13 Dedicated training. (It should be noted that Langenhorst did point out that you can use wire EDM to cut shims by stacking the stock, sandwiching it between two pieces of quarter-inch steel, and cutting off a stack.) Changing the wire size provides one of two benefits. To learn more about other machining and fabricating processes, check out An Engineer’s Guide to Waterjet Cutting, The What, Why and How of 5-Axis CNC Machining and An Engineer’s Guide to CNC Turning Centers. “With wire EDM, you’re working in deionized water, so unless it’s made from 420 stainless steel or something like that, a robot’s not going to last very long.”. “Newer machines are getting better as far as electrode wear goes, but to get high detail on a finished part with a sinker, you generally need at least two electrodes: a rougher and a finisher. Older or less-efficient machines will consume over 1 lbs. This electrode is then carefully plunged into the workpiece, causing sparking over its surface as features close the sparking gap—the distance required for sparking. 82 oete EDM andoo oients o eiaeEDMco Wire Path A. Privacy Policy. In wire EDM, the conductive materials are machined with a series of electrical discharges (sparks) that are produced between an accurately positioned moving wire (the electrode) and the workpiece. This can include disassembly and cleaning of many components and re-calibration of the machine before being put back into production. The die sinker process begins with machining a graphite electrode to form a “positive” of the desired cavity. Wire EDM has grown and expanded to include many more industries that rely upon this unique machining method to produce high accuracy details. The workpiece setup in a Wire EDM requires that the part be suspended out within the confines of the work zone. Deionized water serves as the dielectric in a Wire EDM just as oil serves as the dielectric in a Sinker EDM. When it has a lot of particulate—I call it ‘melted car bumpers’—that’s non-conductive, if you hit one of those, it’s like hitting a stone: you just can’t get through it.”. Of course, some electrically conductive materials still don’t play well with EDM. “Unlike conventional milling, EDM does not encounter limitations with L:D as internal radii features become smaller and workpiece thickness increases. DURATION: NUMBER OF PARTICIPANTS: EXPERIENCE LEVEL: REQUIREMENTS: 3 days: 4: Beginner: Basic mechanical skills: This training is for the following machines series: CUT E, CUT P, CUT P Pro, CUT X 000. Then the final workpiece origin is set by using a canned pick-up cycle in the machine that uses the wire with touch sensing to find part centers or edges. “That doesn’t work too well: it’s way too brittle and the spark energy just shatters it like glass. If you need to rough cut a lot of parts quickly, electrical discharge machining probably isn’t the right process for you. For example, EDM is typically slower than other machining methods, but it also tends to be more predictable, accurate and repeatable. This format is identical to that found in Milling (G90, G91, G00, G01, G02, G03). g Grou. Special tooling vises are also used to hold parts upward of 40 lbs. Wire EDM produces a smooth finish because the wire electrode goes through the entire part, and spark erosion occurs along the entire wire electrode. During operation, the wire electrode originates from a main spool and travels over a series of rollers where precise tension is applied to the wire. for stamping and plastic injection tooling. Copyright © 2021 engineering.com, Inc. All rights reserved. Wire EDM Basics. Wire EDM machines do require a significant amount more maintenance and continuous TLC than other conventional machines such as lathes or mills. To ensure that you’re using the best dielectric fluid for your particular machine, consult its manufacturer. Many machines today have improved and reduced the amount of wire consumption, and the more efficient machines consume 0.5~0.6 lbs. However, if you’re looking for a machining process that’s accurate, precise and stress-free—at least on the workpiece—EDM could be just what you need. Second, a larger diameter wire will provide faster roughing machining speeds, as the larger cross-section of the wire will allow and withstand higher EDM discharge energy without breaking. The most common type of processing performed on Wire EDMs is 1-, 2- or 3-pass machining. You learn . p, DMRL. High-speed EDM hole drilling was designed especially for fast, accurate small- and deep-hole drilling applications. “The biggest thing with metal additive manufacturing is that you have to build on a base plate and then separate the part from that,” he said. All newer machines operate fully submerged under a filtered water dielectric fluid, and high-pressure flushing is … Originally used for making dies from very hard steel, today it is used for hard and soft materials and is often used because of its ability to create a complex shape with relative ease compared to other types of machining options. Maintenance items that are typically performed are primarily cleaning of the rollers, precision wire guides, and indexing of electrical contacts. First, a smaller diameter wire will produce a sharper inside corner radius. The idea showed promise, but it wasn’t until water was added as a coolant that this approach became practical. “The biggest bottleneck to overcome with EDM processing is managing part throughput by maximizing the unattended operation and overall machine utilization,” he said. Best Match; Time: ending soonest. Some of it is conductive enough that you can cut it a little bit, but not very well.”. Only by producing components in-house is it possible to tailor them perfectly to the intended task. Many criteria need to be taken into account. Both the wire and workpiece sit beneath a layer of dielectric fluid. “All of a sudden, they realize that can cut strippers, knockouts, die buttons, inserts, slides, all kinds of parts. Creating wire EDM features. The U/V axis strokes also determine what the maximum taper angle at a specific workpiece thickness can be machined. That’s where sinker EDM is a must.”, The principle advantages of EDM are that the process is very predictable, accurate and repeatable. The areas you can’t do with hard milling are sharp inside corners or very deep, thin ribs. The basic Wire EDM today offers 4- or 5-axis (X, Y, U, V & Z) positioning capability in order to perform complex taper or three-dimensional machining. The most common size range is from 0.004” to 0.012” Ø (0.100~0.300mm), and the most widely used wire size is 0.010”Ø (0.250mm), but there are some machines that are capable of operating with wires as small as 0.0006”Ø (0.015mm). Specifying a wire EDM cutting strategy. Known by many other names, including spark machining, arc machining and (inaccurately) burning, the EDM process is conceptually very simple: an electrical current passes between an electrode and a workpiece which are separated by a dielectric liquid. But this is not the case. Wire EDM machines also entail other consumable wear items that require periodic replacement and care such as filters, DI resin, wire guides, energizer contacts, rollers and bearings, as well as additional items. The vast majority of Wire EDM parts are cut straight, but some may include tapers and varying angles. The machine axis layout consists of a typical X/Y/Z configuration, but there is also a U/V axis that is parallel and stacked on top of the X/Y axis. “The goal is to ensure flawless, unattended machine operation over long hours, as this is where the process gains its productivity and lower manufacturing costs.”. Wire EDM machines use a small, traveling wire electrode to machine complex shapes, which are always through cavities (the wire must pass completely through the workpiece). Most Wire EDM machines contain 5 axes, but only 4-axis simultaneous machining is possible (Z-Axis remains stationary during machining). of wire per hour running 0.010” Ø. THE BASICS OF HIGH-SPEED EDM HOLE DRILLING. Wire EDM cutting, also known as electrical discharge machining, is a process that uses an electrically energized thin wire to slice through metal. “Depending on the complexity of the attachment layer, it can be a pain to separate them. 9 followers edm_basics8 (18 edm_basics8's feedback score is 18) 100.0% edm_basics8 has 100% Positive Feedback. "We are seeing more and more EDM cells with specialized automation," said Raucci. The most efficient method for Wire EDM programming is using a dedicated software module designed for Wire EDM operations, as this will provide many helpful and time-saving processing tools for Wire EDM that cannot be performed using software designed for milling. We're working on a new Wire EDM is commonly seen today in high- or short-run production applications, such as parts for the medical and aerospace industries. EDM 101: Electrical Discharge Machining Basics, potentially replace so-called subtractive processes, The What, Why and How of 5-Axis CNC Machining, An Engineer’s Guide to CNC Turning Centers, An Introduction to Interferometers for Highly Accurate Engineering Measurements, An Introduction to Advanced Composite Fabrication, Optimizing Machining and Workholding for Metal Additive Manufacturing, How Traditional Machine Tool Alignment Processes Compare to Laser Calibration, Controlling the spacing of the sparking gap between the electrode and workpiece, Cooling the heated material to form the EDM chips, Removing EDM chips from the sparking area. Stark, Harding and Beaver continued to refine their process, which eventually became the basis for the vacuum-tube EDM, which made it possible to increase spark frequency from 60 times per second to well over 1,000. All. The maximum part size that can be machined by Wire EDM is dictated by the capacity of the X/Y/Z strokes, the size of the work tank, and the weight capacity specifications of a particular machine. Electrodes are typically manufactured by milling, but can be also be machined with Wire EDM depending on geometry detail. As that process improved, there’s less sinker cavity work that needs to be done. While there are many specialized forms of electrical discharge machining, industrial EDM machines are commonly grouped into three categories: All three types operate on the same principal of erosion by electrical discharge discovered by Joseph Priestley in 1770, but their history, methods and applications are notably different. Side Refine Panel. EDM-WIRE Basic Training. of EDM. Often presented under the banner of Industry 4.0 or the fourth industrial revolution, the conjunction of various technologies, including robotics, artificial intelligence and the Industrial Internet of Things (IIoT)—will forever change the manufacturing sector, from machine tools to quality assurance. (Image courtesy of Makino. Wire EDM machines are capable of operating with a range of different wire diameter sizes. “In general, the EDM process is reserved for parts with smaller feature sizes and higher accuracy requirements (+/- 0.0005” or +/--0.012mm or finer accuracy).”, “Once you have a wire EDM in your shop, it becomes very obvious that you can do a lot more with it than just what you bought it for,” said Langenhorst. This adds time, cost and can alter the finished parts’ dimensions, especially if the heat treatment process is not properly controlled. Wire EDM (Vertical EDM's kid brother), is not the new kid on the block. A Basic 4 or 5 Axis Wire EDM Machine. Compared with conventional machining—from basic CNC turning all the way up to 5-axis—EDM has certain advantages and disadvantages. ), Cabin brackets for the Airbus A350 XWB with support structure. Beaumont Fast Hole EDM Drill. “All EDM machining is performed unattended, so the direct labor rate and manufacturing cost are typically lower for EDM than other methods,” said Pfluger. (Image courtesy of Makino. Learn the main functionalities to perform with the EDM Wire technology. g. ineerin. (Image courtesy of, Robotic cell for producing graphite electrodes. EDM Drilling will not typically achieve the same level of tolerance or surface finish as Sinker or Wire EDM, but the process is commonly utilized to prep parts with start holes … Changing the wire size provides one of two benefits. V I (-ve) Fig. As the dielectric fluid breaks down—whether as the result of age or contamination—the risk of unstable discharge increases. The workpiece must be electrically conductive. A long, thin copper or brass alloy wire rolled on spools replaces the saw blade to remove material. The result is often a reduced need for post-processing or surface treatment. Fundamentals and Principles of EDM Srinivasa Rao Nandam, Sc ‐ ’E’ , Mechanical En. The movement of the U/V axis tip or tilt the wire at different angles to produce tapers, but the wire will always follow a straight linear path that is at an angle. Wire EDM machines are capable of operating with a range of different wire diameter sizes. North American EDM Supplies - Your international source for EDM consumables, With the care and concern of a friend. Machines can also be equipped with additional 1- or 2-axis rotary tables that enable access to multiple sides of a workpiece in a single setup. Registration on or use of this site constitutes acceptance of our Courtesy Agie Figure 5:1 Precision Wire EDMing Understanding the Wire 5 EDM Process. Die-sinker EDM machines typically use hydrocarbon oil for their dielectric fluid, into which both the workpiece and spark are immersed. There is a physical limit to how much power can be applied to and sustained by any given wire size before the wire (think of it as a small filament) melts, breaks, or fractures. Wire EDM cutting uses rapid, controlled, repetitive spark discharges from the wire to the workpiece, thereby eroding the metal away. experience for engineering.com stories! However, the solutions to the material issues in these cases lie in variations of electrode materials and slower EDM cycle times. As the name implies, wire EDM uses a thin wire for an electrode. The ability to create accurate and precise holes, even in hardened or exotic materials has been a key development for several advanced technologies, such as EDM-created cooling holes in high-temperature alloy turbine blade sections. (Image courtesy of, (Left) Side-clamp vise. The wire travels through the workpiece (where EDM machining occurs) being guided by two precision alignment wire guides and is then routed into a collection basket in the rear of the machine. Programming a Wire EDM shares many parallels to 2D Milling; however, the program start location is commonly at the center of a pre-drilled hole. High frequency pulses of alternating or direct current is discharged from the wire to the workpiece with a very small spark gap through an insulated dielectric fluid (water). Differences are found in the M-code commands, as Wire EDMs have many specialty M-codes that are specific to Wire EDM operations, such as threading and cutting of the wire. FAST4AXES is a seamlessly in CATIA V5 NC integrated software solution for offline programming and simulation of wire EDM processes, for 2 up to 4 axis wire EDM machines. NORTH AMERICAN EDM SUPPLIES 1-800-270-2627 www.edmsupplies.com Nothing on the machine is more irritating or disrupting than wire problems. (Image courtesy of, GF Machining Solutions AgieCharmilles Die Sink EDM. This tutorial introduces you to the basics of creating wire EDM toolpaths. Just like any chip, they need to be removed from the cutting zone, which is accomplished by flowing the dielectric fluid through the sparking gap. What Characteristics Should Be Examined When Comparing Two Different EDM Wire Types? One the desired shape has been machined, the parts are then hardened by one or more heat treatments. The most common size range is from 0.004” to 0.012” Ø (0.100~0.300mm), and the most widely used wire size is 0.010”Ø (0.250mm), but there are some machines that are capable of operating with wires as small as 0.0006”Ø (0.015mm). These also provide an easy adjustment method to level and align the part within the machine. As it exists today, die sinker EDM is used to create complex cavity shapes in tool and die applications, such as metal stamping dies and plastic injection molds. It looks at: Setting up your material and wire thickness. This permits a “film cooling” process, which allows jet engines to operate at higher temperatures for greater durability and efficiency. The upper head can be offset in the U & V axis tipping the Wire at an angle to the lower guide. Save this seller. 1 shows schematically the basic working principle of EDM process. Wire EDM Tooling; Other; All; Auction; Buy It Now; Sort: Time: ending soonest. This necessary time can be kept to a minimum with proper investment in workholding tooling that provides faster and more precise setups.”, “The bottleneck for sinkers is electrode manufacturing: if you don’t have a graphite mill in-house, then you’re going to have to outsource your electrodes and the more complicated the shape, the longer the lead time,” said Langenhorst. Anything beyond 1 Pass (rough cut) machining is referred to as a skim or trim cut, and each consecutive pass improves both part accuracy and surface finish. Conventional wisdom suggests that wire EDM is only competitive when dealing with expensive and difficult-to-machine parts. 1 Schematic representation of the basic working principle of EDM process. The combination of predictability, accuracy and repeatability—combined with its relatively slow machining speed—explains why EDM is most at home in low-volume operations with tight tolerances, such as the aerospace and medical device industries. Machines are capable of cutting and re-threading the wire automatically, which greatly extends unattended machining time. Obviously, it takes a submerged machine to do that, and in some cases you get this honeycomb structure between the workpiece and the baseplate that acts as a heatsink; if you don’t build that just right, it can trap powder, which really raises hell on the controls for an adaptive wire EDM machine.”, Pfluger agreed, adding that “Sinker EDM is also commonly used to finish certain features on additively manufactured components, such as small features that require high accuracy and finer surface finishes than what can be produced by additive manufacturing.”. Reliable operation of Wire EDM machines is strictly dependent on several operational maintenance items. The Wire EDM process is similar to a band saw that’s used to cut wood, metal or plastic. CAMWorks for Solid Edge Wire EDM software has been designed and developed specifically for programming 2 through 4-axis Wire EDM CNC Machines - unlike most CAM systems that use modified milling commands for their EDM programming modules. Once it’s been used, the wire is no longer perfectly round. With sinker EDM, you can automate the machining electrode tool as well as the workpiece. Most modern machines are capable of achieving accuracies in the range of ±0.0002” (±0.005mm), but high accuracy machine models are available that are provide finer tolerances. As with any manufacturing technology, EDM faces certain hurdles that must be overcome to ensure that you’re getting the most from your machines. “It’s very common to automate a VMC mill with a sinker EDM so the mill can produce the needed electrode tool with a robot automatically moving it between the different machines,” said Pfluger. Beyond understanding the necessary consumable elements, Wire EDMs encounter machine downtime while these items are tended to during machine maintenance. It was introduced in the late 1960s', and has revolutionized the tool and die, mold, and metalworking industries. 22 nd December 2015, 14:30 Hr s. gg p, Wh t i EDM Wh. If you’ve enjoyed this third lesson in our 6-part Back to Basics series, be sure to stay tuned for future segments as we reflect on our industry and celebrate the building blocks that have led us to the fascinating EDM advancements that we encounter each day. “Over the years, sinkers have become less and less utilized because of high-speed hard milling. Wire EDM machines use a small, traveling wire electrode to machine complex shapes, which are always through cavities (the wire must pass completely through the workpiece). All rights reserved. Wire cut EDM (or WCEDM) discharges the electrified current by means of a taut thin wire, which acts as the cathode and is guided alongside the desired cutting path, or kerf. In contrast, wire EDM machines normally use deionized water, into which only the sparking area is immersed. Simulating wire EDM toolpaths First, a smaller … Most machines support taper angles up to 15 degrees, but there are special wire guides that allow angles up to 45 degrees. Some of these are the same bottlenecks the arise for other machining processes, as Pfluger explained. Control electronics can compensate to a certain extent, but the only real solution is to continually pump clean dielectric fluid through the cutting zone to flush it. The dielectric fluid acts as an electrical insulator unless enough voltage is applied to bring it to its ionization point, when it becomes an electrical conductor. Wire threading..... 25 Dialogue-assisted navigation..... 27 Professional mode ... to high-performance EDM machines from world market leader Mitsubishi Electric. The more conductive particles in the fluid, the more difficult it is for the machine to maintain stable electrical thresholds inside the sparking gap. Commonly called a “hole popper” this machine uses a rotating conductive tube for its electrode and a continuous flow of dielectric fluid (usually deionized water) to flush the cut. EDM Drilling machines, which are commonly referred to as EDM hole poppers or small-hole EDM, create small diameter holes in parts faster than conventional mechanical drilling and will achieve higher L:D (length to diameter) depth ratios. It is probably the most exciting and diversified machine tool developed for this industry in the last fifty years, and has numerous advantages to offer. People have tried bandsaws, grinding, slitting wheels and all different kinds of things, and we’ve done quite well cutting the parts off the base plates using wire EDM. Heterogenous materials, especially those with impurities, can also present a problem for EDM, as Langenhorst explained: “With carbon fiber composites, even though they are electrically conductive, the adhesives in them create some problems because they’re non-conductive. Pfluger pointed out another advantage to using electrical discharge machining for parts with small or complex features: “The EDM process becomes more attractive as workpiece materials become harder, and as the part geometry becomes smaller and deeper,” he said.