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Wire EDM is a process for creating precision wire parts in a very short time, often under one day. Hundreds of wire EDM shops are part of the Xometry network, giving Xometry nearly infinite capacity to make the parts you need. This process enables the production of high-quality parts at a very competitive price.
CNC wire edm machining
CNC machining of wire EDM parts is a high-tech process that allows wire EDM parts to be manufactured to extremely accurate tolerances. The process is versatile enough to process a variety of electrically conductive materials, including hard metals, soft metals, and tough, gummy materials. It can also be used to machine exotic alloys.
The process can be used to machine parts that have intricate features, like sharp internal corners. It uses a taut wire to cut these parts. It is most effective for machining materials such as hard metals and thick plates, but it is not suitable for plastics. This process is slow, but can accommodate very difficult shapes and is ideal for applications requiring tight tolerances. This process has a long history and has been developed to become faster and more flexible. In fact, it is now commonly used in 3D contouring and in drilling, finishing, and deburring.
CNC machining of wire EDM parts is a high-tech process that offers a range of benefits to companies. The process can produce a range of parts, from prototypes to production-grade components, without the need for post-processing. Wire EDM is particularly useful in the production of small-scale parts with tight tolerances.
Non-contact machining process
A non-contact machining process for wire-embedded parts has several advantages. First, it produces a surface that is smooth without requiring polishing. Second, this type of machining process does not require contact with the workpiece, which means that delicate parts or materials can be machined without distortion. Third, this type of machining does not require a high-speed machine or polishing after the process is completed. Although it has some limitations, it is still an excellent method for manufacturing prototypes and small parts. Lastly, EDM has an excellent accuracy level, making it a preferred method of manufacturing parts for the automotive and aerospace industries.
The two most important components of an EDM process are wire and dielectric water. The wire can be made from a variety of materials and has varying diameters, but most wire used in wire EDM processes is brass or copper. The wire can also be coated with zinc to improve its speed and surface finish. The zinc coating allows the wire to withstand higher temperatures and to be more consistent.
Surface finish
Surface finish is an important factor for wire-embedded parts. These parts are often called out in part prints. The finish is important because it affects the sliding ability of the surface. A high-quality surface finish is vital for sealing and bearing applications. Here are a few ways to improve the surface finish of wire-embedded parts:
Wire EDM machines are ideal for complex 2-dimensional shapes. They can also machine very thin walls without distortion. Additionally, they are able to cut cases, exotic alloys, and other materials with great precision. The precision of wire-embed parts is excellent, and the surface finish is a 32 RMS or better.
The process used for wire-embedded parts has two different approaches. One involves the use of one-cut wire cutting technology. This involves passing the wire through a solid part. As it gets closer to the surface, a spark gap is added to the wire. As the wire approaches the part’s surface, the gap becomes narrower. During the final finish pass, the offset is often as small as three microns. This step can take six or seven skim cuts, and even seven skim passes can be necessary to achieve Ra finish.
Chip production
When cutting thin materials, wire EDM parts can be extremely cost-effective. One way to maximize its efficiency is by chaining several small shapes together. In addition, this type of machining allows critical dimensions to be cut without skimming the entire profile. This process is a good choice for producing injection molds and other complex parts that require high accuracy and repeatability.
Previously, wire EDM was considered a niche service, but today, it is a vital process in aerospace and medical manufacturing. From tiny precision parts to complex medical devices, wire EDM can ensure the highest quality parts, without stress or burrs. These components are often made of high-tech materials that must be free of debris in order to meet strict safety standards.
In addition, wire EDM parts can be made to tight tolerances, allowing for high-quality detail. However, wire machines require regular maintenance to ensure they remain running smoothly. The process should also be closely monitored during the production run to ensure it meets specifications.
