THE JOB SHOP

ABOUT WIRE EDM

Our Wire EDM services offer precision, reliability, and versatility for cutting conductive materials like steel and aluminum. With capabilities to achieve tolerances as tight as +/-.0001 and the ability to cut intricate parts without generating burrs, we ensure high-quality results. Unlike traditional machining, our process does not produce cutting forces, making it ideal for delicate or heat-sensitive parts. We also invest in top-tier stainless steel tooling and maintain optimal flatness during setup to ensure accuracy. Whether you need complex parts with taper cuts or heat-treated components, our Wire EDM machines deliver the precision and efficiency required for even the most demanding applications.

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WHAT IS WIRE EDM?

Wire EDM is a method used to cut any conductive materials, such as steel and aluminum, with a thin brass or molybdenum traveling wire electrode that follows a CNC (Computer Numerical Control) programmed path. Wire diameters range from .001 to .013, with .010 being the most typical, leaving a .005 corner radius that is acceptable in most applications. Wire EDM machines are rated to cut their best through heat-treated steel up to 2 inches thick. The hardness of the workpiece material does affect the overall speed. Flatness is also a factor; the flatter the workpiece, the faster the process. The traveling wire never touches the part being machined. Consequently, Wire EDM machines do not take the same abuse as a CNC mill, meaning they tend to stay more accurate over time compared to mills and lathes.

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The process is fascinating. The wire is charged with a special type of electricity, not the same as what comes from a typical 110V outlet at your house. As a spark jumps from the traveling wire electrode in precise bursts, it simultaneously melts a small portion of the conductive workpiece. Deionized water is used to flush the particles from the gap.

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In reality, the electricity excites the molecules in the deionized water, which facilitates the EDM (Electrical Discharge Machining) process. The traveling wire electrode is simply a tool for transferring the power to the water. It is important to note that the water used is specially deionized, with a very specific low conductivity, which makes it less prone to transferring electricity compared to tap water. This is why you don't get electrocuted if your body comes into contact with the water.

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CNC Wire EDM machines can independently move six machine axes to generate taper cuts, turn-and-burn type parts like rotors, and stamping dies with angle relief for slugs. The taper capability depends on the machine manufacturer; for example, Mitsubishi EDM can achieve about 15 degrees, while Charmilles EDM can cut 45 degrees or more. Wire EDM can achieve accuracy to within +/-.0001, depending on how many passes are made, as the process is slow. Most shops find that one rough cut (one pass of the wire) is more accurate than they ever worked before, usually within a couple of tenths. No burrs are generated.

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Wire EDM is ideal for manufacturing delicate parts since there are no cutting forces involved. In general, heavy investments in stainless steel tooling are required to hold parts flat and square while the EDM process is taking place. The tooling must meet high standards, as the wire never touches the workpiece. However, the machines apply high water pressures (300 psi or more) directly to the part being machined. This can cause vibration and movement of the workpiece, presenting difficulties during part setup. The primary benefit of Wire EDM is that parts are cut after heat treatment, so there is no heat-induced warpage to deal with, which is especially useful for intricate parts.

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Some machines can cut parts that are 30 inches tall, though this is a very slow process and is only used in extreme applications where the shape cannot be made in any other way.