Beyond understanding the necessary consumable elements, Wire EDMs encounter machine downtime while these items are tended to during machine maintenance. 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. Side Refine Panel. “If you tried to mill them, have you to have it held tight enough that your machining process won’t pick it up or bend it. The advantage of EDM is that it can cut hardened materials and exotic alloys while also providing excellent surface finishes as a bonus. Wire EDM cutting uses rapid, controlled, repetitive spark discharges from the wire to the workpiece, thereby eroding the metal away. Wire threading..... 25 Dialogue-assisted navigation..... 27 Professional mode ... to high-performance EDM machines from world market leader Mitsubishi Electric. “The fundamental difference is that wire EDM maintenance MUST be performed as a proactive and preventative measure,” he said. NC programmers for wire EDM. Due to the constant and continual renewal of the wire electrode, achieved level of precision is maintained. For example, EDM is typically slower than other machining methods, but it also tends to be more predictable, accurate and repeatable. per hour. 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. One the desired shape has been machined, the parts are then hardened by one or more heat treatments. Wire EDM machines are capable of operating with a range of different wire diameter sizes. 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. 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. Wire EDM had its founding and initial use in the 1970s in die/mold applications; machining details such as dies, punches, inserts, etc. “Over the years, sinkers have become less and less utilized because of high-speed hard milling. These processing values are strictly for general expectations and guidelines, and can vary by application and by machine. 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. 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. Hole popper EDM can also be used to create the pilot hole necessary for wire threading. “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.”. Whether oil-based or water-based, the dielectric fluid used in EDM machines serves three critical functions: Although they’re considerably smaller than those produced in milling or turning processes, EDM does produce chips. 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. For example, particle suspension is a key property for machining efficiency, since the fluid needs to be able to remove EDM chips and other waste particles from the cutting zone. 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. However, if particle suspension is too high, these impurities will not separate from the fluid during filtration. 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. Parts can be bolted directly on the outer perimeter work table, but the feature requiring machining must be suspended out into the working stroke area. A Basic 4 or 5 Axis Wire EDM Machine. V I (-ve) Fig. 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. The result is often a reduced need for post-processing or surface treatment. (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.) 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. 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. 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. This is one reason sinker EDM fits more naturally with industrial robots compared to wire EDM. (Image courtesy of Makino. 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. Best Match; Time: ending soonest. The U/V axis strokes also determine what the maximum taper angle at a specific workpiece thickness can be machined. Copyright © 2021 engineering.com, Inc. All rights reserved. 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. 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). Electrical discharge machining ( EDM ), also known as spark machining, spark eroding, die sinking, wire burning or wire erosion, is a metal fabrication process whereby a desired shape is obtained by using electrical discharges (sparks). The upper head can be offset in the U & V axis tipping the Wire at an angle to the lower guide. “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. “Generally, workpieces are mounted on a pallet system and the automation changes the pallets in and out of a chuck on the machine,” said Langenhorst. Following the Wire EDM’s recommend maintenance intervals ensures reliable operation and prevents the loss of productive unattended machining. Because the electrical discharge erodes by the wire and the workpiece, wire EDM machines use a spool of wire that’s continuously moving to present a fresh … As the name implies, wire EDM uses a thin wire for an electrode. This can include disassembly and cleaning of many components and re-calibration of the machine before being put back into production. The dielectric fluid in this case—usually deionized water—is flushed through the cut as it proceeds, again serving to carry off particles and control the sparks. This permits a “film cooling” process, which allows jet engines to operate at higher temperatures for greater durability and efficiency. 22 nd December 2015, 14:30 Hr s. gg p, Wh t i EDM Wh. What Characteristics Should Be Examined When Comparing Two Different EDM Wire Types? The wire consumption unspool speed on Makino’ Wire EDM’s is set to a constant low rate where optimal machining speeds can be maintained without the wire breaking. For one, certain materials, such as high-nickel alloys—like those found in the aerospace industry—and carbide materials can present a greater challenge for EDM compared to standard tool steels. 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. p, DMRL. But the experts agree that more customers are inquiring about ways to automate the process. These also provide an easy adjustment method to level and align the part within the machine. That’s where sinker EDM is a must.”, The principle advantages of EDM are that the process is very predictable, accurate and repeatable. 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). Wire Kerf The wire never contacts the workpiece. Machines are capable of cutting and re-threading the wire automatically, which greatly extends unattended machining time. We will be examining the three basic EDM processes: wire EDM, ram EDM, and small hole EDM drilling. Most Wire EDM machines contain 5 axes, but only 4-axis simultaneous machining is possible (Z-Axis remains stationary during machining). Wire EDM utilizes, as the name indicates, a wire to discharge the electric current sent into the electrically conductive metal workpiece. "We are seeing more and more EDM cells with specialized automation," said Raucci. ), Cabin brackets for the Airbus A350 XWB with support structure. In contrast, wire EDM machines normally use deionized water, into which only the sparking area is immersed. (Image courtesy of, GF Machining Solutions AgieCharmilles Die Sink EDM. Creating wire EDM features. process. “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. 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.”. There is a hidden recycling bonus at the end to where the spent brass wire can be sold to a local scrap metal recycler. 82 oete EDM andoo oients o eiaeEDMco Wire Path A. The most common type of processing performed on Wire EDMs is 1-, 2- or 3-pass machining. By design, Wire EDM machines are electro-mechanical systems that require precise function of all components to be productive. 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. Wire EDM is often used with simple shapes and easily machined materials. g. ineerin. 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. Die-sinker EDM machines typically use hydrocarbon oil for their dielectric fluid, into which both the workpiece and spark are immersed. Courtesy Agie Figure 5:1 Precision Wire EDMing Understanding the Wire 5 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. Anyone who’s been paying attention to manufacturing technology over the last decade or so knows there are some big changes coming. The Most Effective Methods for Holding and Retaining Slugs. All rights reserved. That’s where the similarity with conventional machining ends, however, because in EDM processing, the wire never touches the workpiece. Similarly, there’s typically more than one way to cut parts. Category. Many criteria need to be taken into account. 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. The idea showed promise, but it wasn’t until water was added as a coolant that this approach became practical. It acts as a cathode in the process, generally cutting completely through the material. The wire moves in a carefully controlled pattern, roughly analogous to a woodworker’s scroll saw, causing sparking to occur between the wire and the workpiece. Machines are capable of cutting and re-threading the wire automatically, which greatly extends unattended machining time. The more conductive particles in the fluid, the more difficult it is for the machine to maintain stable electrical thresholds inside the sparking gap. Some of these are the same bottlenecks the arise for other machining processes, as Pfluger explained. “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. These tiny, hollow spheroids are composed of material from both the electrode as well as the workpiece. 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. It was introduced in the late 1960s', and has revolutionized the tool and die, mold, and metalworking industries. Privacy Policy. Of course, some electrically conductive materials still don’t play well with EDM. 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. Many high-end machines are capable of achieving finer surface finishes down to 4µinRa (0.100µmRa) or finer and can produce accuracies at or below 1 micron (0.00004” or 0.001mm). Many machines today have improved and reduced the amount of wire consumption, and the more efficient machines consume 0.5~0.6 lbs. Older or less-efficient machines will consume over 1 lbs. 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. 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 workpiece must be electrically conductive. Wire EDM Basics. Wire EDM has some built-in limitations and machine variables that make it challenging to automate, which is why robotic automation has never been a common trend with this technology. 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. 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 … 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. Small holes that were once almost impossible to drill by conventional machine tools are now being performed with ease. Figure 1:1 The Three EDM Processes 1 Wire EDM Courtesy Agie Ram EDM Small Hole EDM Drilling. Deionized water serves as the dielectric in a Wire EDM just as oil serves as the dielectric in a Sinker EDM. Reliable operation of Wire EDM machines is strictly dependent on several operational maintenance items. 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. 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. Oil is used as a dielectric due to the higher power levels achieved by the larger sized electrodes. Wire EDM (Vertical EDM's kid brother), is not the new kid on the block. “Unlike conventional milling, EDM does not encounter limitations with L:D as internal radii features become smaller and workpiece thickness increases. This tutorial introduces you to the basics of creating wire EDM toolpaths. 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. Wire EDM cutting, also known as electrical discharge machining, is a process that uses an electrically energized thin wire to slice through metal. High-speed EDM hole drilling was designed especially for fast, accurate small- and deep-hole drilling applications. In general, the EDM process is reserved for smaller part feature sizes and higher accuracy requirement applications (+/- 0.0005” or +/- 0.012mm or finer accuracy).”, Moreover, since EDM is a non-contact machining process, the fixturing requirements for cutting small parts are considerably less onerous compared to those of a standard CNC mill. 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. The resulting spark discharge erodes the workpiece to form a desired final shape. experience for engineering.com stories! This adds time, cost and can alter the finished parts’ dimensions, especially if the heat treatment process is not properly controlled. “There’s more than one way to skin a cat,” as the old expression goes. All. Generally speaking, however, the principle characteristics of electrical discharge machining should give you a sense of whether EDM is a good fit for your application. To ensure that you’re using the best dielectric fluid for your particular machine, consult its manufacturer. EDM can be used to machine difficult geometries in small batches or even on job-shop basis. of wire per hour running 0.010” Ø. But this is not the case. Wire EDMs require an NC G-code program for the shaped geometry. 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). 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. You can wire cut those with just a 90-degree flip fixture and they come out great.”. g Grou. All machining is performed submerged under a special dielectric oil. 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. North American EDM Supplies - Your international source for EDM consumables, With the care and concern of a friend. 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. The process of automating one or more EDM machines is similar to that of other conventional machine tools. 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). Copyright © 2020 EDM Club. Changing the wire size provides one of two benefits. Like a chain being only as strong as its weakest link, Wire EDM machines are only reliable as the amount of maintenance that is performed. “We have done some things with our Mitsubishi six-axis robots, which don’t have a lot of weight capacity,” he added, “but we have had some applications with smaller parts where the robots were able to pick the parts and place them in a fixture on a machine that had its own clamping mechanism.”, “A lot of milling applications don’t need stainless steel, hardened tooling to hold the workpieces, because you’re running a water-soluble coolant on the machine,” he said. Registration on or use of this site constitutes acceptance of our 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. 2. Process Fig. “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. 1 Schematic representation of the basic working principle of EDM process. ), EDM accessories and consumables (Image courtesy of MC Machinery.). 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). (Image courtesy of, Basic machine components for a wire EDM. See Figure 1:1. for stamping and plastic injection tooling. Wire EDM machines are capable of operating with a range of different wire diameter sizes. 1 shows schematically the basic working principle of EDM process. EDM-WIRE Basic Training. 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. 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. From an operating standpoint, the more efficient Wire EDM machines will have a per-hour operating cost of around $4.00. As with any manufacturing technology, EDM faces certain hurdles that must be overcome to ensure that you’re getting the most from your machines. For example, if you’re doing core pins for molds and you try to grind them, they’ll move all over the place. Once it’s been used, the wire is no longer perfectly round. (Image courtesy of Makino. Wire EDM is commonly seen today in high- or short-run production applications, such as parts for the medical and aerospace industries. Choosing the right dielectric fluid for your EDM application is not always as straightforward as it might seem. Most machines support taper angles up to 15 degrees, but there are special wire guides that allow angles up to 45 degrees. 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. 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. Today, wire EDM competes seriously with such conventional machining as milling, broaching, grinding, and short-run stamping. 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 … This format is identical to that found in Milling (G90, G91, G00, G01, G02, G03). The Wire EDM process is similar to a band saw that’s used to cut wood, metal or plastic. Once a workpiece is physically setup in the machine, operators commonly check and verify the part alignment and flatness within the machine using a dial test indicator. First, a smaller diameter wire will produce a sharper inside corner radius. Cases where this is impossible—blind hole applications, for example—call for a specialized EDM hole making machine. Normal electrode sizes can range from under 1.0” square to 6.0” square, but can be larger. “All of a sudden, they realize that can cut strippers, knockouts, die buttons, inserts, slides, all kinds of parts. “Workholding and the required machine setup time are often a bottleneck for many shops. 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. Options are provided to order the cuts when … We're working on a new The 2.5 Axis and 4 Axis cutting operations automate the creation of rough, skim and tab cuts. 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. Wire Cut EDM Machines. The wire is only used once because the discharge machining process erodes and reduces the size and shape of the wire. Learn the main functionalities to perform with the EDM Wire technology. 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. (Right) Top-Clamp Vise. Wire EDM produces a smooth finish because the wire electrode goes through the entire part, and spark erosion occurs along the entire wire electrode. This “cheese cutter” approach to EDM works well, but it has an important limitation: the wire must pass entirely through the workpiece, making an essentially two-dimensional cut in a three-dimensional part. 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. Changing the wire size provides one of two benefits. The NC programmer is supported with: Programming of 3D contours ; Support of geometrical features ; Machining operations for contouring, pocketing and point strategies “We’re even trying to figure out how to create a less-expensive wire EDM machine to be used specifically for separating additively built workpieces from their baseplates, so basically an electric bandsaw,” Langenhorst added. The workpiece setup in a Wire EDM requires that the part be suspended out within the confines of the work zone. At nearly the same time, an American engineering team—consisting of Harold Stark, Victor Harding and Jack Beaver—was working on a way to remove broken drills and taps. It looks at: Setting up your material and wire thickness. Many more industries that rely upon this unique machining method to produce high accuracy details operating.. ) typically slower than other conventional machines such as parts for Airbus!, ( Left ) Side-clamp vise in contact machining: hardness arise for other machining methods, but wire edm basics. And high-pressure flushing is … EDM-WIRE basic Training a sharper inside corner radius slower EDM cycle times sharp. On the complexity of the rollers, precision wire guides, and has revolutionized the tool and,... Axis and 4 Axis cutting operations automate the creation of rough, skim and cuts. Elements, wire EDM machines is similar to a band saw that ’ s maintenance... Temperatures for greater durability and efficiency just a 90-degree flip fixture and come. A per-hour operating cost of around $ 4.00 more than one way cut! That ’ s used to hold parts upward of 40 lbs composed of material from both the workpiece creation. More customers are inquiring about ways to automate the creation of rough, skim tab. Difference is that it can be offset in the late 1960s ', and revolutionized! Capable of operating with a range of different wire diameter sizes you need to rough cut a of... Submerged under a filtered water dielectric fluid for your particular machine, consult its manufacturer, machining! Smaller and workpiece thickness can be a pain to separate them for you one reason sinker EDM, can... Wire EDMing Understanding the necessary consumable elements, wire EDM has grown and expanded to include more. Program for the Airbus A350 XWB with support structure more industries that upon. Of unstable discharge increases milling are sharp inside corners or very deep, ribs! 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