Wire Cut Edm Applications

Tooling applications for wire edm probably the best known application is cutting the profile in extrusion dies.

Wire cut edm applications. Due to its ability to cut complex shapes without the set up times of conventional processes wire electrical discharge machining wedm lends itself to the prototyping or limited run production of miniature gears with a low aspect ratio for use in small mechanisms. Machining typically creates distortion in the area surrounding the cut. Produce almost any part with a single wire cut cut conductive materials ranging from aluminium and copper to graphite with an electrical spark. The principle benefits of edm its excellent surface finish minimal heat affected zone haz and ability to cut hardened materials and exotic alloys make it ideal for certain hole making applications.

Edm technology allows you to achieve extreme accuracy when producing incredibly delicate parts at very high cutting speeds. Edm can be used in everything from prototypes to full production runs and is most often used to manufacture metal components and tools. If a small pilot hole is pre drilled into workpiece wire can be threaded through it to complete the operation using wire edm. Filters and de ionizing units are used for controlling the resistivity and other electrical properties.

Because the process can cut very small pieces it is often an ideal choice for the production of small highly detailed items that would normally be too delicate for other machining options. Nor is this just restricted to die and mould. Wire cut edm is typically used to cut plates as thick as 300mm and to make punches tools and dies from hard metals that are difficult to machine with other methods. The guides are usually cnc controlled.

A hole is first drilled through the die blank often also by edm and the wire is then threaded through. In the wire cut edm process water is commonly used as the dielectric fluid. The wire which is constantly fed from a spool is held between upper and lower diamond guides which is centered in a water nozzle head. The process is best suited for applications requiring low levels of residual stress.

For aluminum extrusion these are usually made from h13 tool steel. Wire edm is particularly valuable for its ability to cut a wide range of hard thick thin and fragile materials without compromising the surface or edge of the material. Wire edm is most commonly used in mold and die manufacturing processes particularly for extrusion dies and blanking punches. Wires made of brass are generally preferred.