Wire EDM

In Wire Electrical Discharge Machining (WEDMing), or Wire-Cut EDM, a thin single-strand metal wire is fed through the work piece, typically occurring while in a submerged tank of dielectric fluid or deionized water. This fluid helps to cool the process and flush away the cut material. The Wire EDM process uses electric current to cut conductive materials leaving a smooth surface that requires no further finishing or polishing.

This process is used to cut plates and to make punches, tools, and dies from any conductive material, including hard metals that are too difficult to machine with other methods, such as; metal allows, graphite, carbide and diamond. The wire is held between upper and lower diamond guides. The guides move in the (X-Y) plane controlled by a CNC, the upper guide can also move independently in the (Z-U-V) axis, giving rise to the ability to cut tapered and transitioning shapes and can control axes movements. This gives the Wire-Cut EDM the ability to be programmed to cut very intricate and delicate shapes. Wire EDMing is commonly used when low residual stresses are desired. Wire EDM has no added residual stress because it has no cutting forces. There is little change in the mechanical properties of a material in Wire EDMing due to its low residual stresses.

The cutting wire never touches the material, the cutting itself is due to the erosion that occurs when a spark forms between the cutting wire and raw material. A typical Wire EDM process with consist of several passes, moving at various speeds. The first passes are typically fast moving, lower accuracy to remove large amounts of material. Later, skim passes, will retrace the cuts at lower speeds, removing less material but improving the surface quality and accuracy of the cut. If complex cut outs are required, a pre-drilled hole through a raw material can be threaded with a Wire EDM and the machine can begin cutting from there. Applications for Wire EDM include the creation of extrusion dies, blanking punches and metal and tool fabrication. Wire EDM serves many industries making components for automotive, aerospace, medical, energy, die/mold, industrial and micro manufacturing. Wire EDMs are also found in numerous job shops across the country as the serve an integral part of the part creation process.

Explore Sodick's Range of Precision Wire EDM Machines!

Super Jet AWT

A new annealing function has been added to Sodick’s conventional jet wire threading system resulting in the world’s fastest auto wire threading device, the “Super Jet AWT”. During the annealing process the wire is heated, stretched and cut. This new function ensures a higher success rate in threading wire through a hole on a submerged workpiece or a small diameter hole. Recommend for using Sodick Hayabusa 200 P5-5.

Advantages of “Super Jet AWT”

• Wire is threaded easily through work pieces with pockets on the top and bottom surface, improving threading success rate.
• New guide options give higher machining precision, longer life and lower running costs.
• Wire tip disposal unit can handle thin wires, while increasing threading reliability.
• Reliable auto threading through wide angle taper guides.
• Improved threading through tall work pieces with annealed and heat cut wire.

Advantages of Machining Parts with Complex Shapes

Without technical know-how, the high precision machining achieved by experienced engineers can now be easily performed by anybody.

In Wire EDMing of parts, the necessities of performing high precision machining on complex shapes with stepped height is increasing. The latest Wire EDM machines from Sodick feature not only high precision and highly responsive linear motors, but the automatic processing and surface finishing of complex shape workpieces without the need for adjusting machining conditions, leading to high speed and high precision machining.

Auto Stepped Height Machining

Due to the latest “Discharging Gap Detection Circuit”, the machine can precisely detect the status of the discharge gap during roughing and finishing and optimum servo control is possible even in the finishing process. Even with workpieces with varying thicknesses, the machine can automatically adjust and even complex shapes can be machined without the need to process machining conditions.

Taper Flex 45

Taper Flex 45 is available as an option for further advanced high angle taper cutting up to 45 degrees. Taper Flex 45 is easy to use and requires no special training. The function consists of three parts, high angle guides, compensation jig and specialized software.