Wire EDM Cutting
Wire EDM (electrical discharge machining) uses an electrically energized
thin brass wire to slice through metal - including difficult-to-machine metals. Wire EDM
creates intricate profiles. The Wire EDM machine uses rapid, controlled, repetitive spark
discharges.
The workpiece must be electrically conductive. It is often
possible to stack and cut workpieces simultaneously. The narrow kerf and dimensional
accuracy make it possible to provide close-fitting parts. Workpiece thickness ranges
from only a few thousands of an inch to several inches.
Possible shapes
Any simple or complex 2D shape - allows cutouts and thin
walls, intricate openings and tight radius contours, both internally and externally.
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Example parts
Punches, dies, stripper plates, gears.
Advantages of Wire EDM Cutting
Cutting intricate shapes and tight radius contours. Low cost when surface
area of cut edge is small or quantity is low.
Specifications for Wire EDM Cutting
 Material - Steel,
super alloys, titanium, aluminum, brass, and most other metals.
Alternative machines
- Punch Fixed (for simple parts), Punch CNC (for thin sheets), Mill 3-Axis CNC (for simple
shapes), Laser Cut (for longer runs of simple parts), Water Jet (for short runs of thick
parts).
Tooling - Wire EDM
cutting requires only software program tooling.
Reducing costs - reduce total cut length, minimize holes or provide a
small gap connecting holes to the outer edge,
minimize number of separate pieces to take advantage of stacking.
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Notes
 Wire
EDM edges are smooth but matte. Typical surface finish is between 16 and 64 microinches.
The edges of the finished work piece will have virtually no burrs. Kerf width 0.001 -
0.012". Sharp internal corners will be slightly rounded (~.008").
Processes: Turning
Milling
Laser Cutting
Water Jet Cutting
Wire EDM
Tapping
Bending
Turret Punching
Fine Blanking
Blanking
Steel Rule Die Cutting
Drawing
Injection Molding
Extrusion
Metal Casting
Thermoforming
Forging
Springs
Wire forming
Powder Coating
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