Cut through the mysteries of this valuable machining technique. Everything you need to know about Wire EDM in one in-depth guide.
For more information, please visit Moly Wire.
Wire electrical discharge machining (Wire EDM) is an efficient, non-contact CNC machining process that uses electrical sparks to erode material from a workpiece.
Wire EDM can machine very hard materials like hardened steel, carbides and super alloys that are difficult to machine through traditional methods. It provides excellent edge quality, surface finish and accuracy within tight tolerances.
Wire EDM offers several advantages over traditional machining:
The Wire EDM process works by generating a series of rapid, repeating electrical discharges between the wire and workpiece submerged in dielectric fluid. The sparks melt and vaporize material in a precise pattern by eroding the workpiece along the path of the moving wire. By carefully controlling the electrical parameters and wire path via CNC programming, intricate shapes can be cut quickly and accurately.
Note:
The key components of a Wire EDM machine include:
Power Supply – Generates the voltage and current required to create an electrical discharge between the wire and workpiece. Supplies voltage in the range of 100-300V. Controls the frequency and intensity of the sparks.
Wire – A thin brass, tungsten, or molybdenum wire that serves as the electrode. Diameters range from 0.05-0.30mm. A precision-guided system controls wire tension and positioning.
Workpiece – The electrically conductive material being cut. Is positioned and clamped by a fixture and must make contact with the dielectric fluid.
Dielectric Fluid – Deionized water that surrounds and cools the wire. Removes debris and controls the discharge gap.
CNC System – Controls the movements of the wire and workpiece via CAD/CAM programming to achieve the desired cuts.
The Wire EDM process depends on several critical parameters:
Voltage – The potential difference applied between the wire and workpiece to create sparks. Higher voltage enables cutting of thicker materials.
Pulse Duration – The length of each electrical discharge. Affects how much material is removed with each spark.
Wire Tension – The tensile force applied to the wire. Higher tension improves cutting speed and accuracy.
Wire Speed – The linear feed rate of the wire through the workpiece. Faster speed reduces cutting time but sacrifices surface quality.
Dielectric Flow Rate – The flush rate of deionized water around the wire. Needed to remove debris and excess heat.
In summary, while other methods have some advantages, Wire EDM provides a unique balance of accuracy, precision, and speed for machining hard, conductive materials, making it a go-to choice for critical applications across many industries.
Wire EDM can cut any electrically conductive material, making it well-suited for cutting hard metals and alloys. Common materials cut include:
Major industries using Wire EDM include:
Ideal applications for Wire EDM involve:
The diameter of the wire electrode is one of the key factors determining cutting speed and accuracy in Wire EDM.
Using a smaller diameter wire, typically 0.004” to 0.010” Ø (0.1-0.25 mm), allows higher cutting speeds since the reduced mass permits faster movement and quicker discharges. However, the faster speed comes at the cost of lower accuracy and increased wire vibration/instability, which can cause corner rounding.
Larger wire diameters above 0.010ӯ (0.25 mm) cut at slower speeds but offer better accuracy and reduced vibration.
A Ra 30 μin (≈ 0.8 μm) can be achieved. Higher current and lower feed rates improve surface finish.
Post-EDM processes like vibratory finishing, passivation, and electro-polishing can further improve finish. Deionized water must be closely monitored.
Common wire breakage causes include inadequate flushing, high feeds/speed, inferior wire quality, and wire guides misalignment.
Poor cuts result from contaminated dielectric, incorrect polarity, or bad workpiece grounding. Periodic maintenance and wire inspection essential.
Risks include electric shock, fire hazards from flammable dielectrics, and potential inhalation of vaporized metals. EDM produces noxious fumes so adequate ventilation is essential. Sparks and high voltages are hazardous – machines require guarding and interlocks. Appropriate PPE like gloves, eye protection and breathing masks should be worn.
Modern EDMs have automatic wire threading/handling and CNC control for complex geometries. Wire guide cam systems improve accuracy of multi-cavity molds. Customized fixturing increases flexibility for batched production.
Reduce operating costs by using lower grade less expensive wires for roughing cuts and high quality wires for finishing. Minimize wasted machine time through efficient programming and scheduling.
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Oct 18, 2023
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Molybdenum Wire
HSG molybdenum wire supplier offers molybdenum wireMolybdenum wire: is a kind of consumable when electric discharge wire cutting processing, wire cutting machine processing workpiece continuous movement of fine wire called electrode wire (also called electrode), it can pulse spark discharge on the workpiece, cutting metal forming. Contact us and get molybdenum wire price today!
Specification of Molybdenum Wire
Specifications for molybdenum wire:
Molybdenum Wire Types
For more Tungsten Barinformation, please contact us. We will provide professional answers.
Diameter (inch)
Tolerance (%)
Molybdenum Wire for EDM
0.0024" ~ 0.01"
±3% wt
Molybdenum Spray Wire
1/16" ~ 1/8"
±1% to 3% wt
Molybdenum Wire
0.002" ~ 0.08"
±3% wt
Molybdenum Wire(clean)
0.006" ~ 0.04"
±3% wt
Grade
Mo-1
The impurity content is not more than 0.01%
Fe
0.01
Ni
0.005
Al
0.002
Si
0.01
Mg
0.005
C
0.01
N
0.003
O
0.008
Application of Molybdenum Wire
Pure molybdenum wire GMPM. 1 1 Used for winding wire core, support, lead wire, heating element, molybdenum foil belt, wire cutting, auto parts spraying, etc.
Lanthanum molybdenum wire GMHI-M. 1 2 is used for glass sealing parts of winding wire core wire, molybdenum foil belt, furnace heating material, wire cutting high temperature components, etc.
Yttrium molybdenum wire GMHYM. 1 3 used for support, lead wire, electron tube reed, gate, furnace body heating material, high temperature components.
Wire cutting special molybdenum wire GMPM. 1, GMHI.M. 1 2 for all kinds of non-ferrous metals, steel and magnetic materials cutting processing. It has the characteristics of high strength, good discharge performance, high surface finish, fast cutting speed, long life and so on.
Production Process of Molybdenum Wire
High purity molybdenum wire and its production method, relates to the molybdenum products production process of metal materials, especially the production method of high purity molybdenum wire. The invention adopts TMA-52 chelating agent dissolved in deionized water, the TMA-52 chelating agent solution formed as MoO2 raw material detergent, and then the MoO2 after washing is dried, and then the molybdenum powder is successively reduced, the molybdenum billet is pressed, the molybdenum billet is sintered, the molybdenum bar is forged, and finally the molybdenum wire with content ≥99.984% is generated by drawing.
Features of Molybdenum Wire
01.
Ultra-high tensile strength;
02.
High surface finish, good stability, high cutting accuracy;
03.
Small elongation, small tight wire;
04.
Large curvature, consistent wire diameter, not easy to break wire, long life;
05.
Can increase the high frequency power, improve the roughing efficiency; Accurate measurement, vacuum packaging, prevent oxidation mildew, can be stored for a long time.
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