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Wire EDM

Electrical discharge machining (EDM), also known as spark machining, spark eroding, burning, die sinking, wire
burning or wire erosion, is a manufacturing process whereby a desired shape is obtained by 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." The process depends upon the tool
and work piece not making actual contact.
History of EDM Manufacturing

Electrical discharge manufacturing originated in the 1960s when researchers in the Soviet Union discovered Wire EDM as a
method for cutting steel to make tools. In the United States, an engineer named David H. Dulebohn of the Andrew Engineering
Company combined the Soviet EDM technology with a computer that used optics to follow drawings. Dulebohn’s
development led to the creation of the CNC EDM machines we use today. CNC EDM machines became available for the first
time in 1976, and since then, EDM technology and CNC Machining have continued to evolve
Advantages of Wire EDM Machining
• EDM machines offer a broad range of benefits that other manufacturing methods cannot match. Some reasons to choose a Wire EDM Machine

include:

• Precision: When you need highly accurate machining, EDM manufacturing is your best option. It is capable of making cuts that match your designs

within ± 0.0001”.

• Intricacy: Wire EDM is an excellent option for manufacturing delicate and intricate parts. With Wire EDM, it is possible to manufacture the same

intricate part over and over again with the same accuracy.

• Shorter lead times: Because the EDM process is so accurate, it makes it possible to significantly shorten the lead time by getting it right on the first

try. Decreasing the time it takes to get a product from the prototype phase to the marketplace.

• Less set up time: EDM manufacturing reduces the need for tooling, which in turn lessens the amount of time that it takes to set up.

• Tapers: EDM machining is useful for cutting long tapers that other machining methods cannot produce.

• Accurate internal cuts: Square-edged internal cuts are difficult to produce with other machining methods, but Wire EDM makes it possible.

• Better results: EDM machining is capable of producing parts that do not have burrs or require tooling. Wire EDM also creates a better surface finish

than other forms of manufacturing.


Limitations of EDM

• Metal-removal rates are low.

• Material to be machined must be electrically conductive.

• Rapid electrode wear can become costly.

• Electrodes smaller than .003 in. in diameter are impractical.


What Kind of Materials Can Be Used
Materials like steel are difficult to cut or mold without adding heat first. Wire EDM makes it possible to cut steel
through and other materials without applying heat. EDM machining works best with materials that conduct
electricity, such as:

 Bronze  Stainless steel These materials can be very costly. A good way to keep costs
 Copper  Hast alloy low is to live by the old adage, “measure twice and cut once.”
 Tungsten  Titanium When machining results in inaccurate cuts or fails to reproduce
 Carbon graphite  Kovar parts with the same level of accuracy, these expensive materials
 Carbon steel can go to waste. Because EDM machining is so accurate, it can
 High alloy prevent waste of raw materials and keep your project cost-
 Inconel efficient.
Why Wire EDM is using?
Concerns about residual stress are often the primary reason why manufacturers choose
Wire-Cut EDM over other methods. Residual stress can contribute to premature failure
of a part, so to avoid creating residual stresses during the manufacturing process is to
extend the life of the part. Wire EDM creates minimal residual stress. Moreover,
preventing residual stress eliminates the need to relieve those stresses – this is just
another example of how Wire EDM makes the manufacturing process efficient.
Makes possible cutting most shapes and contours from flat plate materials Complex
shapes: tapers, involutes, parabolas, and ellipses
Principle of EDM
• Controlled metal-removal technique where electric spark used to cut (erode)
work piece.
• Takes shape opposite to that of cutting tool.
• Electrode (cutting tool) made from electrically conductive material.
• Dielectric fluid surrounds both tool and work.
• Servo mechanism gives gap .005 to .001 in. between work and tool.
• Direct current of low voltage

Makes possible cutting most shapes and contours from flat


plate materials Complex shapes: tapers, involutes, parabolas,
and ellipses
Wire EDM machine
Operating Systems
Four main operating systems of wire-cut electrical discharge machines
i. Servo mechanism
ii. Dielectric fluid
iii. Electrode
iv. Machine control unit
Servo Mechanism
Controls cutting current levels, feed rate of drive motors, and
traveling speed of wire

Automatically maintains constant gap of .001 to .002 in. between


wire and work piece Important there be no physical contact

Advances work piece into wire, senses work-wire spacing, and slows
or speeds up drive motors to maintain proper arc gap
Dielectric Fluid
Usually deionized water Serves several functions:

1. Helps initiate spark between wire and work

2. Serves as insulator between wire and work

3. Flushes away particles of disintegrated wire and work from gap to prevent shorting

4. Acts as coolant for both wire and workpiece


Electrode
Spool of brass, copper, tungsten, molybdenum, or zinc wire ranging from .002 to .012 in. in diameter

(2 to 100 lb)

Continuously travels from supply spool to take up spool so new wire always in spark area.

Both electrode wear and material-removal rate from workpiece depend on: Material's electrical and

thermal conductivity, its melting point and duration and intensity of electrical pulses
Characteristics of Electrode Materials
• Be good conductor of electricity.

• Have high melting point.

• Have high tensile strength.

• Have good thermal conductivity.

• Produce efficient metal removal from workpiece.

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