Electric Wire Cutting Machine Trends and Developments

Posted on Sep 25, 2020

Electric Wire Cutting Machine

Electric wire cutting machines (EDM) are used in non-traditional machining processes that use thin, charged copper or brass wires as electrodes to accurately and accurately cut any conductive material. In the wire EDM process, the wire carries the charge on one side, and the workpiece carries the charge on the other side.

When the wire is close to the part, the attractive force of the electric charge generates a controlled spark, which melts and evaporates the microscopic particles of the material. The spark also removes the tiny wires, so after the wire passes through the workpiece once, the machine discards the used wire and automatically advances the new wire.

The process is lightning fast with literary thousands of sparks each second. However, the wire never touches the workpiece. When the wire cutting machine is performing electric wire cutting, the dielectric solution of de-ionized water is used to continuously cool and flush the processing area. Let’s take a look at some applications and trends of electric wire cutting machines and compare them to laser cutting machines, as well.


Applications of Electric Wire Cutting Machines

The electric wire cutting machines enables the company to create extremely complex products that have been carefully designed from various types of metals, including 3-D shapes. This process is widely used in industries such as aviation prototyping, electronics, and parts manufacturing. Other industries include jewelry designers, metal shops, car manufacturers, and companies that provide parts for various industries. EDM machining is very suitable for cutting in narrow areas and has strict tolerances. It is also suitable for cutting hard materials that are difficult to process by other methods or maybe deformed by manual cutting.

For parts that need to be processed very smoothly and have no internal burrs, electric wire cutting machines are a reliable choice. It is also possible to obtain a smooth profile by grinding off 0.005 inches of bumps that occur when the workpiece is dropped from the wire. Wire-cut electrical discharge machining is used to cut hardened metal plates with a thickness of 300 mm, which are usually difficult to process in any other way. It can also be used when the final part needs low stress. Wire EDM has low cutting force, can remove material, and usually, no change in mechanical properties is seen. Electric wire cutting machines are used for the manufacture of extrusion dies, blankets, and equipment.


Advantages of Electric Wire Cutting Machines

Electric wire cutting machines are most suitable for relatively low-volume products that require strict manufacturing tolerances. Industries that utilize EDM-made components include the semiconductor industry, medical, and instrumentation. Electric wire cutting machines have a range of benefits, such as:

  • Complex forms, otherwise difficult to manufacture with conventional cutting tools
  • Quite stiff and very flexible content
  • Traditional cutting instruments can harm the components for very small workpieces due to extreme cutting pressure
  • The instrument and the workpiece have no immediate touch
  •  Responsive elements and fragile materials can then be treated without deformation
  • You will obtain a nice surface finish
  • It is easy to perforate a very small hole

:: Read more : Let’s look at the Pros and Cons of a EDM Wire Cut Machine

Electric Wire Cutting Machines vs. Laser Cutters

For processes that require strict tolerances, wire cutting machines and laser cutting machines are both good choices. Each uses advanced thermal technology to cut the work material and mold it. However, EDM and laser difference could make a machine a better choice to suit your business needs. For example, wire cutting machines are more suitable for cutting thick steel plates than laser cutting machines, while laser cutting machines are limited to accurately cutting thinner materials. Ultimately, choosing the right solution depends largely on your requirements. Here are some differences you should be aware of.

Laser cutting is a precision manufacturing method for cutting metal and many other materials. A high-power beam generated by an external source excites electrons through the optical cavity. The electrified electrons emit photons of light, which reflect back and forth in the resonator, and amplify the photons through further stimulation. These photons from the laser machine are emitted in a very small, highly concentrated beam.

The laser beam is so powerful that all objects in its path will instantly melt, vaporize, or burn to achieve precise cutting. In very thin materials, tolerances can be as small as about 0.002 inches, otherwise tolerances of ±0.005 inches can usually be achieved on laser cutting systems. The 3 kW of power generated will easily cut through materials that are no more than a quarter-inch thick, including aluminum, stainless steel, copper, and brass. The speed and precision associated with laser cutting often make it a very cost-effective and efficient choice in manufacturing.


Final Thoughts

Electric wire cutting machines are an effective process for removing unconventional materials, which can meet various processing requirements proposed by manufacturers. The main goal of the wire cutting machine (EDM) process is to obtain the best parameters without sacrificing its performance indicators. It is usually used for machining and micro-machining of parts with complex shapes, varying hardness, high profile accuracy, and strict dimensional tolerances.

However, compared with other non-traditional processing technology (such as laser cutting technology), the main disadvantage of this process is the relatively low processing speed, which is largely due to its thermal processing technology.

Choosing the best parameter conditions is critical to the successful operation of the electric wire cutting machine. The main input parameters of the wire cutting machine are pulse on time, pulse off time, peak current, gap voltage, wire feeding, wire tension, etc. Response time criteria include removal speeds (MRR), rugging rate, cutting distance, quality of the rate, size variation, etc. The criteria for accuracy and accurate engineering goods were met effectively via the wire cutting process in the age of modern science and technology.


:: Read more : Wire Cut EDM Machines - more than just tooling and mold-making equipment

Electric Wire Cutting Machines on IMTS-Exhibition.com

You can find many electric wire cutting machine manufacturers on our site. Just head to our product section or check out our search function to find hundreds of manufacturers in our product database.  If you want to learn more about electric wire cutting related questions and applications make sure to check out our other blog entries.

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