CONTENTS : Chapter

Introduction Basic Wire EDM Machines Dielectric Systems EDM Wire Flushing Cutting Speed Generator Accuracy Work holding devices 5 10 12 15

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1 1 5 6

EDM overview Electric discharge machining (EDM), sometimes colloquially also referred to as spark machining, spark eroding, burning, die sinking or wire erosion, is a manufacturing process where by a desired shape is obtained using electrical discharges (sparks). Material is removed from the work piece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the electrodes is called the tool-electrode, or simply the tool or electrode, while the other is called the work piece-electrode, or work piece. When the distance between the two electrodes is reduced, the intensity of the electric field in the volume between the electrodes becomes greater than the strength of the dielectric (at least in some point(s)), which breaks, allowing current to flow between the two electrodes. This phenomenon is the same as the breakdown of a capacitor (condenser) (see also breakdown voltage). As a result, material is removed from both the electrodes. Once the current flow stops (or it is stopped - depending on the type of generator), new liquid dielectric is usually conveyed into the inter-electrode volume enabling the solid particles (debris) to be carried away and the insulating proprieties of the dielectric to be restored. Adding new liquid dielectric in the inter-electrode volume is commonly referred to as flushing. Also, after a current flow, a difference of potential between the two electrodes is restored to what it was before the breakdown, so that a new liquid dielectric breakdown can occur. In 1770, English Physicist Joseph Priestley studied the erosive effect of electrical discharges. Furthering Priestley's research, the EDM process was invented by two Russian scientists, Dr. B.R. Lazarenko and Dr. N.I. Lazarenko in 1943. In their efforts to exploit the destructive effects of an electrical discharge, they developed a controlled process for machining of metals. Their initial process used a spark machining process, named after the succession of sparks (electrical discharges) that took place between two electrical conductors immersed in a dielectric fluid. The discharge generator effect used by this machine, known as the Lazarenko Circuit, was used for many years in the construction of generators for electrical discharge. Additional researchers entered the field and contributed many fundamental characteristics of the machining method we know today. In 1952, the manufacturer Charmilles created the first machine using the spark machining process and was presented for the first time at the European Machine Tool Exhibition in 1955. In 1969 Agie launched the world's first numerically controlled wire-cut EDM machine. Seibu developed the first CNC wire EDM machine 1972 and the first system manufactured in Japan. Electrical discharge machining is a machining method primarily used for hard metals or those that would be very difficult to machine with traditional techniques. EDM

typically works with materials that are electrically conductive, although methods for machining insulating ceramics with EDM have also been proposed. EDM can cut intricate contours or cavities in pre-hardened steel without the need for heat treatment to soften and re-harden them. This method can be used with any other metal or metal alloy such as titanium, hastelloy, kovar, and inconel. Also, applications of this process to shape polycrystalline diamond tools have been reported. EDM is often included in the non-traditional or non-conventional group of machining methods together with processes such as electrochemical machining (ECM), water jet cutting (WJ, AWJ), laser cutting and opposite to the conventional group (turning, milling, grinding, drilling and any other process whose material removal mechanism is essentially based on mechanical forces). Ideally, EDM can be seen as a series of breakdown and restoration of the liquid dielectric in-between the electrodes. However, caution should be exerted in considering such a statement because it is an idealized model of the process, introduced to describe the fundamental ideas underlying the process. Yet, any practical application involves many aspects that may also need to be considered. For instance, the removal of the debris from the inter-electrode volume is likely to be always partial. Thus the electrical proprieties of the dielectric in the inter-electrodes volume can be different from their nominal values and can even vary with time. The inter-electrode distance, often also referred to as spark-gap, is the end result of the control algorithms of the specific machine used. The control of such a distance appears logically to be central to this process. Also, not all of the current flow between the dielectric is of the ideal type described above: the spark-gap can be short-circuited by the debris. The control system of the electrode may fail to react quickly enough to prevent the two electrodes (tool and work piece) to get in contact, with a consequent short circuit. This is unwanted because a short circuit contributes to the removal differently from the ideal case. The flushing action can be inadequate to restore the insulating properties of the dielectric so that the flow of current always happens in the point of the inter-electrode volume (this is referred to as arcing), with a consequent unwanted change of shape (damage) of the toolelectrode and work piece. Ultimately, a description of this process in a suitable way for the specific purpose at hand is what makes the EDM area such a rich field for further investigation and research. To obtain a specific geometry, the EDM tool is guided along the desired path very close to the work, ideally it should not touch the work piece, although in reality this may happen due to the performance of the specific motion control in use. In this way a large number of current discharges (colloquially also called sparks) happen, each contributing to the removal of material from both tool and work piece, where small craters are formed. The size of the craters is a function of the technological parameters set for the specific job at hand. They can be with typical dimensions ranging from the nano scale (in micro-EDM operations) to some hundreds of micrometers in roughing conditions.

The presence of these small craters on the tool results in the gradual erosion of the electrode. This erosion of the tool-electrode is also referred to as wear. Strategies are needed to counteract the detrimental effect of the wear on the geometry of the work piece. One possibility is that of continuously replacing the tool-electrode during a machining operation. This is what happens if a continuously replaced wire is used as electrode. In this case, the correspondent EDM process is also called wire EDM. The tool-electrode can also be used in such a way that only a small portion of it is actually engaged in the machining process and this portion is changed on a regular basis. This is, for instance, the case when using a rotating disk as a tool-electrode. The corresponding process is often also referred to as EDM grinding. A further strategy consists in using a set of electrodes with different sizes and shapes during the same EDM operation. This is often referred to as multiple electrode strategy, and is most common when the tool electrode replicates in negative the wanted shape and is advanced towards the blank along a single direction, usually the vertical direction (i.e. z-axis). This resembles the sink of the tool into the dielectric liquid in which the work piece is immersed, so, not surprisingly, it is often referred to as die-sinking EDM (also called conventional EDM and ram EDM). The corresponding machines are often called sinker EDM. Usually, the electrodes of this type have quite complex forms. If the final geometry is obtained using a usually simple shaped electrode which is moved along several directions and is possibly also subject to rotations often the term EDM milling is used In any case, the severity of the wear is strictly dependent on the technological parameters used in the operation (for instance: polarity, maximum current, open circuit voltage). For example, in micro-EDM, also known as -EDM, these parameters are usually set at values which generate severe wear. Therefore, wear is a major problem in that area.

Basic EDM Wire Cut Machines The thickness of wire is usually use is 0.25mm. It must be cut with fire or the specific cutter wire is attached to the machine to make sure that the end of the wire will be sharp. The wire must be place according to the direction on the machines. It must be inserting until both roller is move. It shows that we insert it with the right ways. The materials that can cut use EDM wire cut is mild steel, stainless steel, aluminum, copper, graphite and titanium. The table at the machine is using to ties the project. The project must be ties with the < 90 degree. If not, the final result might be not as thinking. The table can move in 2

directions. It is x-axis and the y-axis. The nozzle is made from ceramic because it so fragile so, when both of it accidently meets, it will be break and will not harm the machine. The thickness of the project must be considered. If the length is too far from the project, the wire will be not tense and the result of the project will not accurate. If the length is to near, the nozzle will break. Machine EDM wire it have 2 types. It has flash and the submerged. For the machine submerged, the project must be immersing in the water fully. At the end of upper nozzle, it have a sensor that detect the water level for not over the limit. The water temperature must be at the range 24 to 25 degrees and the water radiant must be at the range 7.5 to 8.1. It also has coolant system. In this machine, pneumatic system is use for the compressor. The type of the compressor is the silent type. In wire electrical discharge machining (WEDM), also known as wire-cut EDM and wire cutting,a thin single-strand metal wire, usually brass, is fed through the workpiece, submerged in a tank of dielectric fluid, typically deionized water.

Dielectric Systems Deionized water is usually used as the dielectric so that high-pulse frequencies can be achieved. The dielectric filtering and Deionizing system play a key role in preventing excessive wire breakage. (Note: Dielectric oil is available as a dielectric on some machines. Ionization of the oil is much slower than DI water causing a substantial decrease in machining speed.) Deionized water is the principle dielectric medium used on Wire EDM machines. Water is used to push chips and debris out of the Wire slot and cool the Wire and work piece. Since water is not the insulator that dielectric oil can be, ionization occurs rapidly. Because of this, water will retain current even after the voltage is turned off. Resins help to maintain the conductivity level of the water. This conductivity level is described as Microsiemens (s) and the desired level of conductivity that should be maintained for a given application may vary from material to material. If the conductivity level is too high during machining you may experience excessive Wire breakage. Dielectric flushing pressures have been increased (i.e., up to 300 psi) over the past few years in order to boost cutting speed.

These higher pressures coupled with advances in power supplies and Wire composition have all had a major impact on machining speed EDM Wire In wire electrode discharge machining or wire-cut EDM, a thin single-strand metal wire is fed through the work piece. This process is similar to contour cutting with a band saw, a slowly moving wire travels along a prescribed path, cutting the work piece. This process is used to cut plates as thick as 300mm and to make punches, tools, and dies from hard metals that are too difficult to machine with other methods. It also can intricate components for the electronics industries. The wire, which is constantly fed from a spool, is held between upper and lower diamond guides. The guides move in the x-y plane, usually being CNC controlled and on almost all modern machines the upper guide can also move independently in the z-uv axis, giving rise to the ability to cut tapered and transitioning shapes and can control axis movements in x-y-u-v-i-j-k-l-. This gives the wire-cut EDM the ability to be programmed to cut very intricate and delicate shapes. The wire is controlled by upper and lower diamond guides that are usually accurate to 0.004 mm, and can have a cutting path or kerfs as small as 0.12 mm using 0.1 mm wire, though the average cutting kerf that achieves the best economic cost and machining time is 0.335 mm using 0.25 brass wire. The wire usually made of brass, copper, tungsten, or molybdenum and multi-coated wire. The wire diameter typically about 0.3mm for roughing cuts and 0.2mm for finishing cuts. The wire should have high electrical conductivity and tensile strength, as the tension on it is typically 60% of its tensile strength. The wire usually is used only once, as it is relatively inexpensive compared to the type of operation it performs. It travels at a constant velocity in the range of 0.15 to 9 m/min, and a constant gap (kerf) is maintained during the cut. The trend in the use of dielectric fluids toward clear, low viscosity fluids. The reason that the cutting width is greater than the width of the wire is because sparking also occurs from the sides of the wire to the work piece, causing erosion. This "overcut" is necessary, predictable, and easily compensated for. Spools of wire are typically very long. For example, an 8 kg spool of 0.25 mm wire is just over 19 kilometers long. Today, the smallest wire diameter is 20micrometres and the geometry precision is not far from +/- 1 micrometre.

Brass Coated Wire Specification

Item Brass Hard Wire Brass Soft Wire Cobra A Coated Wire Cobra D Bronco X Bronco HX Dia. (mm) 0.15 0.20 0.25 0.30 0.15 0.20 0.25 0.30

Molybdenum wire High refined molybdenum wire are hydrogen reduced to molybdenum power, having a purity of 99.9 minimum. The power is isostatically pressed and sintered into rod of a uniform fine grained structure. The rod are then drawn down to the required size. Dimension : Outside Diameter from 0.0011" to 0.0070" Packing : 500m or 1km/spool Specification : Material Dia. (Inch) 0.0011 0.0019 0.0028 0.0031 0.0043 0.0047 0.0051 Dia. (mm) 0.03 0.05 0.07 0.08 0.11 0.12 0.13

Molybdenum &

Tungsten wire Tungsten wire is made from doped powders, that is powders in which small quantities of some material have been incorporated. The powders are consolidated under high pressure and sintered at high tenperatures and worked by rolling and swaging to heavy rod suitable for drawing. Dimension : Outside Diameter from 0.0020" to 0.0120" Packing : 500m or 1km/spool Specification : Material Dia. (Inch) 0.0055 0.0059 0.0071 0.0079 0.0098 0.0118 Dia. (mm) 0.14 0.15 0.18 0.20 0.25 0.30

Tungsten wire

Flushing Flushing is important to achieve stable condition. It plays very important role as far as cutting speed concerned. Both the nozzle supper and lower should be just about 0.22 mm away from the work piece, otherwise cutting performance drops considerably. Also both the nozzles should also be checked periodically for damages, scratches or slight damage on the contact edge affect cutting speed. Purity of the water should be machined by firm displacements of filters.

Cutting Speed As stated before, EDM Die Sinkers can operate at high average currents (i.e., above 100 Amps when using large electrodes). A Wire EDM machine is limited to the amount of average current that can be used due to the small contact area of the (Wire) electrode. The first Wire EDM machines were slow by todays standards, rated at a mere 1-1/2 to 2 in2/hr machining speeds. Unlike Die Sinkers, these early machines were extremely delicate instruments. Even at these slow machining rates, Wire EDM opened up whole new applications for EDM. The EDM process is not "magic". With these improvements in machining rates we must keep in mind that the accuracy and precision of the initial (roughing) operation will determine the number of subsequent operations (i.e., skim cuts). "Total time as it relates to part quality is the key to machining performance!" There are a number of things that can influence the machining speed of a CNC Wire EDM:

Figure 5 Things that Impact Machining Speed

The surface area of the Wire will determine the average amperage that can be applied to the cut. As the Wire diameter becomes smaller or the work piece thinner, the amount of current that can be applied to the cut drops.

Though it stands to reason that a larger Wire diameter will provide better cutting speed there are other things to consider. For example, accuracy may be adversely affected the faster you machine. Overall downtime replacing worn contacts and general upkeep will also increase, not to mention the overall consumption of the Wire itself.

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Wire is not the only consumable that is used faster as machining increases. Wire contacts, DI resin, filters and guides are all consumed at a faster rate. Higher maintenance can be expected which results in some machine downtime. Obviously the earning capacity of a CNC machine tool is more valuable than a few dollars worth of Wire unless the Wire is simply being wasted. Depending upon the Wire being used, the few dollars an hour can translate into thousands of dollars a year. The type of Wire will also impact overall cost and performance. Though standard brass is used more than any other Wire type by a large margin (up to 75%), premium coated Wires offer enhanced performance for certain types of applications. The outer coating melts rapidly cooling the Wire and increasing the size of the spark gap, providing better flushing. Sold by the pound, EDM Wire costs between $4 a pound for brass to $12 ~ $14 a pound for premium Wires. The chart above gives an example of Wire consumption that can be used to calculate costs.

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Automatic Wire Threading Probably the most important development for Wire EDM machines in terms of real productivity was the invention of the Automatic Wire Threader (AWT). As the story goes, the original auto-threader was developed in the early eighties by an EDM job shop in Europe that was dissatisfied with the productivity of their one Wire EDM machine. Though early Automatic Wire Threaders were not known for high reliability, when they worked, they provided superior throughput over a machine without one. The Automatic Wire Threader made it possible for work to be scheduled into the Wire EDM machine based upon the needs of the operator rather than the length (time) of cut. In general, the auto-threader alone can improve your capital equipment pay back on a Wire machine by 2 or 3:1. Improved productivity is only one benefit to the threader. The flexibility in how the operator might approach a specific application, or how one might program a difficult job, can be enhanced by taking full advantage of an AWT system. If, for instance, the part to be machined is going to "move" prior to skim cutting you might consider machining the part in steps using multiple start (auto-thread) locations to hold the part firmly in place. Accuracy and surface finish can also be improved in just such an application. Most threaders today utilize a water jet system to transport the Wire between the upper and lower guides. Because of the small size of the Wire electrode and the complexity of the entire transport system, the Automatic Wire Threader must be maintained according to the manufacturers recommendations. Failure to properly clean or maintain this valuable machine feature will cause lost production time and money.

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Generator Unlike a Die Sinker that uses long On-Times during roughing operations a Wire EDM uses peak current for very short duration in order to machine a part. The Wire EDM cut uses high (peak) current pulses with short On-Times and relatively short Off-Times times. The result is that extremely high spark frequency is achieved. Since deionized water is used as a dielectric instead of oil (which is a true insulator) there is much less concern over Delay-Time (during ionization). Even though resin is used to deionize the water it does remain charged following an EDM pulse. This leads to a problem known as electrolysis

As machining current is applied in the cut the water becomes charged. Residual current stays in the water continually eating away at the workpiece. This electrochemical reaction in the work tank can cause damage to the integrity of a part. The parts surface can be damaged or discolored and rust may form. Electrolysis will adversely affect the work material, causing unwanted pitting and cracking in tool steels or causing cobalt depletion in carbide. Depending upon the application and use of the part being produced, premature failure may be the end result.

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By alternating the voltage, residual current is eliminated thus preventing the water from remaining charged and causing electrolysis and oxidation of the workpiece.

As can be seen, there are fewer pulses per length of time using this type of pulse generation. It makes sense that the machine will cut slower. It may be worth machining slower if the part produced is better and lasts longer.

Accuracy Accuracy, like any other machining process, must be considered at the beginning of the job. The way in which a part is rough machined will have some impact on how long finishing takes. If we push the Wire through a thicker work piece at the fastest possible speed we will probably produce a bow or belly in the part after the first pass.

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If the deviation in the middle of the part is excessive it may be very difficult to correct with secondary "skim" passes. Since the Wire is flexible even under tension and does not physically contact the work, it may simply bend or bow to the existing shape when skimming the part. The sparks will push the Wire away from the work, recutting the existing shape. Though putting more "tension" on the Wire may help to eliminate some of the problem, it may also increase the number of Wire breaks. Even if skim cutting is successful, the number of passes to eliminate the error may take longer. If the initial roughing pass is slower, producing a more accurate part to begin with, fewer skims are necessary. Similar to conventional machining, if the first cut is too rough (inaccurate) you can expect to spend more time finishing the piece.

Corner accuracy is another area that newer Wire EDM machines have addressed well.

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Though older Wire machines can produce very accurate pieces, the cutting speed of newer machines has caused problems with corner accuracy. Machining a 2.00" thick piece at a cutting rate 25in2/hr will not produce an accurate corner. No one will ever accuse Wire EDM machines of being fast when compared to a High Speed Machining Center. Therefore it is obvious that corner inaccuracy is not caused by overshoot of the servo drive system. The problem is caused by the position of the thin Wire electrode after it leaves the guide. Once the Wire enters the workpiece the same force that can cause bow or belly in the part also pulls the Wire out of location. This can result in leaving excess stock on an inside corner and gouging an outside corner. Though systems and/or software have been developed to counteract this problem, it will only correct the Wire error near the guide. It will not necessarily correct the shape in the middle of a (thicker) piece. Depending upon the application, improved corner accuracy can be enhanced by altering the programmed shape in some way. Even with advanced controls and programming systems, some applications may still require some form of (programmed) path correction. It can take time and multiple test cuts to get a modified programmed shape just right.

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Determination of finish-cutting operation number and machining-parameters setting Good rigidity and the dynamic characteristic of the machine are pre-requisites to achieving optimal machining performance. The setting of machining parameters relies strongly on the experience of operators and machining-parameters tables provided by machine tool builders. It is difficult to utilize the optimal functions of a machine owing to their being too many adjustable machining parameters. The offset is important in process planning and its value is always given in WEDM machining parameters setting tables. Inappropriate offset value leads to unsatisfactory accuracy, and will reduce the surface quality of the machined part also. Because of the non-contact characteristic of electrical discharge and gap-width estimation of multi-cuts, determining an optimal offset value in advance is difficult and still a challenge.

Rough Cutting

Finish cutting

Fig. 16. A schematic plan view of: (a) rough and; (b) finish, cutting of WEDM.

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The finish-cutting operation number and parameters setting of WEDM are the main concern. The influence of machining parameters (pulse-on time, table feed, flushing, distance between the wire periphery and the work piece surface, and machining history (i.e. rough cutting conducted before finish cutting)) on the machining performance (gap width, surface roughness, white layer depth and finish-cutting area ratio) are analyzed first. The Taguchi quality design method and numerical analysis are used to find significant factors affecting the machining performance. Mathematical models relating the machining parameter and performance are established by regression, and non-linear programming using the feasible-direction algorithm is used to obtain the optimal machining parameters. Based on experimental data and numerical analysis, a practical strategy of multi-cut WEDM process planning from rough to finish cutting is proposed and verified. Experiments were carried out on a Wire-EDM machine with an iso-energy pulse generator, developed by the Industrial Technology Research Institute (ITRI), Taiwan. The work material, electrode and other machining condition are given in Table 1. According to the Taguchi quality design concept , a L18 mixed orthogonal arrays table was chosen for the experiments (Appendix A). Based on experience and related literature, six machining parameters: pulse-on time (Ton); pulse-off time (T off); table feed (Feed); flushing pressure (P); distance between wire periphery and work piece surface (D ww, Fig. 1); and machining history (i.e. rough cutting conducted before finish cutting, (His) ); were chosen for the controlling factors and each parameter was designed to have three levels denoted by 1, 2 and 3, as shown in Table 2.

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The influence of finish-cutting parameters on machining performance

With analysis of variance (ANOVA) and the statistical F-test (Appendix B), it is found that Ton and Dww are the two dominant factors on the machining performance in the finish cutting process.

Fig. 17. Illustration of the surface generation mechanism in finish cutting. In order to obtain specified dimensional accuracy and surface quality, and release then residual stress and heat deformation, multi-cut process planning from rough to finish cutting is necessary. The optimal machining parameters for each finish cutting operation can be obtained by seeking the maximum machining speed under the constraints of surface roughness, white layer depth and other constraints. A strategy is proposed and the feasible-direction non-linear programming method is adopted to solve this problem.

Fig. 18. Drum shape after rough cutting.

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Fig. 19. Illustration of offset value calculation

Fig. 20. Showing: (a) the surface appearance of the workpiece (SEM photograph); and (b) the white layer depth (SEM photograph).

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An attempt has been made to determine the number of machining operations and machining parameters efficiently in WEDM. Qualitatively, the pulse-on time (Ton) and the distance between the wire periphery and the work piece surface (Dww) have been found to be significant factors in finish cutting performance (gap width, surface roughness, finish-cutting area ratio). It has also been found that a medium Dww (about - 30 m in this research) can achieve a better surface roughness, but the whole surface will not be machined. In other words, adjusting Ton and Dww can control the finish cutting process. Applying the feasible-direction non-linear programming method, optimal machining parameters can be obtained. Experimental results show that the approximate mathematical models can predict the machining performance within an acceptable error. Moreover, a strategy to determine the finish-cutting operation numbers and the parameters setting has been proposed and verified. It is concluded that rough-cutting process planning under maximum metal removal rate and finish cutting process planning using Model 3 of surface roughness reduction, can achieve minimum machining time. The proposed approach, compared with that of a well-skilled operator, can achieve a better surface quality and take less machining time and, in particular, accurate dimensional accuracy can be obtained.

Work piece Holding Device Several years ago it was not uncommon for Wire EDM tooling to sit unused in a box. After all, what would you do with all that tooling if you didnt have an Automatic Wire Threader. There really isnt much need to incorporate multiple setups on a machine table if threading is manually performed. The average shop used "one part on; one part off" type of operation! With the proliferation of auto-threaders over the past few years the need for a systematic approach to tooling not only seemed appropriate, but was necessary. Original systems designed for Wire EDM machines worked well up until flushing pressures increased dramatically in order to boost cutting speeds. When machining rates reached 20 in/hr it became apparent that the tooling had to be strengthened.

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First, it was difficult to hold a part firmly because of the overhang of the part into the work zone. Secondly, the additional flushing pressures during roughing combined with the overhang caused excessive vibration, and therefore problems maintaining accuracy. Wire EDM Tooling is far more rugged today than ever before and also provides the user the ability to totally integrate the manufacturing process between multiple machines. With enhanced machine and tooling repeatable accuracies (1 to 2 microns) it has become easier to move parts from machine to machine very accurately, opening up a whole new realm of possibilities.

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Fig 22 : Clamp direct on machine table

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Fig 23 : Clamp at Jig & Fixture

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Advantages of EDM Wire 1. The Machining of Complex Geometric Forms Complex, contoured shapes can be produced in one piece rather than several, in the exact configuration that is required. 2. The Rapid, Economic Production of Prototypes and Low Run Parts The ability to accurately machine complex designs, can eliminate or reduce fixture and tooling costs for one of a kind or low run production parts. Formed through the wire EDM process, parts can be immediately used in assembly, with little or no additional finishing. 3. Precise Machining of Pre-hardened Materials Because hardened materials can be EDM eroded, the need for the heat treatment of machined parts is eliminated, avoiding potential distortion. 4. Machining to Tight Tolerances, Avoiding Distortion and Stress Very low machining forces allow tight tolerances of up to 2 microns to be achieved. With little or no stress imparted into the work only light clamping is necessary. Thin materials can also be machined without distortion. 5. The Accurate and Economic Machining of Exotic Materials Exotic materials including A-286 Superalloys, medical grade stainless, titanium, Hastelloy, tungsten carbide, molybdenum, aluminium alloys and copper can all be machined. Better utilisation of valuable materials is provided through chipless machining. 6. Absolute Consistency Between Machined Parts. Because with wire EDM there is no contact between the cutting wire and the surface, there is no tooling wear and absolute consistency can be achieved on every machined part.

The Limitation Of EDM Wire Cut The limitation of EDM wire cut is this machine only can operate on conductor material only. This machines cannot cut soft material and insulator such as paper, wood, nylon, teflon and rubber. It also limited to the size that not to more than the size of table.

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