Wire EDM Services (WEDM)
Wire EDM (Electrical Discharge Machining) is one of the most precise metalworking methods available in industry. The technology uses the electroerosion process to shape electrically conductive materials. A thin metal wire acts as the working electrode moving between special guides. The process occurs without direct mechanical contact, eliminating deformation of the workpiece material.
Advanced CNC machines control the wire movement according to the programmed machining path. High-energy electrical discharges cause melting and vaporization of microscopic material particles. A dielectric in the form of deionized water cools the machining zone and flushes away the resulting debris. The process enables achieving dimensional tolerances on the order of a few micrometers.
CNC Partner specializes in providing wire EDM services for industry. The facility equipped with modern WEDM machines handles orders from single prototypes to production runs numbering thousands of pieces. Experienced specialists ensure the highest quality workmanship while maintaining competitive turnaround times.
Advantages of Wire EDM:
- Exceptional dimensional accuracy – tolerances up to 0.001 mm with surface roughness Ra below 0.2 µm
- Machining of hard-to-cut materials – hardened steels, superalloys, titanium, conductive ceramics
- Complex geometric shapes – capability to produce the most intricate contours and patterns
- No mechanical forces – eliminates risk of deformation when machining thin components
- Minimal material loss – very narrow cutting gap saves costly raw materials
- Sharp internal corners – ability to create corners with a radius of 0.003 inch
- Thermal stability – low process temperature protects material structure
- Material versatility – machining all electrically conductive metals
The WEDM method allows machining parts of various sizes. Modern machines enable cutting parts exceeding dimensions of 1000x600x400 mm. The technology is also effective for producing miniature components with nanometric tolerances.
What is wire cutting?
Wire cutting utilizes the phenomenon of electrical discharge machining controlled by electrical pulses. A special generator produces a high potential difference between the working wire and the material being processed. The sparks generated, with temperatures of several thousand degrees Celsius, melt microscopic volumes of metal.
The working wire, made of brass or copper, moves continuously during processing. The guide system ensures stable positioning of the electrode relative to the workpiece. CNC numerical control manages the movement trajectory according to the machining program. Deionized water serves as a dielectric as well as a cooling and flushing medium.
Parameters of the wire cutting process:
- Wire diameter – from 0.02 mm to 0.33 mm depending on the application
- Cutting speed – from 10 to 300 mm²/min depending on material and thickness
- Operating voltage – 80-400 V controlled by the pulse generator
- Pulse duration – microseconds for precise erosion control
- Dielectric pressure – 0.1-2 MPa for effective flushing
- Process temperature – 20-60°C depending on processing intensity
The process can last from several minutes for simple parts to over 100 hours for the most complex geometries. Thermal stability of the machine is crucial for maintaining dimensional accuracy during prolonged operations.
Wire EDM Machinery Fleet
+GF+ CUT 300SP
Year: 2016
Working Area: 550 x 350 x 400
+GF+ CUT 300SP
Year: 2016
Working Area: 550 x 350 x 400
What materials are used to manufacture dies and punches?
Dies and punches require materials of the highest quality to ensure durability and wear resistance. High-carbon tool steels are characterized by the hardness and strength necessary in forming processes. The mechanical properties of the material determine the tool’s lifespan under operational conditions.
The wire EDM process allows for precise shaping of even the hardest steel grades. This technology enables machining of heat-treated materials without risking structural damage. CNC Partner manufactures dies and punches from a wide range of specialized materials.
Popular steel grades for dies and punches:
- Tool steels – 1.2312, 1.2085, WNL, WCL, WCLV providing high hardness
- Structural steels – MNV, NC11LV, NC10 with increased strength
- Case-hardening steels – 18H2N2, 20HG, 18HGT for working surfaces
- Powder steels – Vanadis 4 Extra, Elmax, Nimax with homogeneous structure
- Special steels – Toolox 44 with controlled hardness
- Carbon steels – with carbon content of 0.6-1.5% for various applications
The choice of material depends on the tool’s purpose and working conditions. Parts exposed to high loads require steels with increased mechanical strength. Components operating in corrosive environments need alloying additions that enhance chemical resistance.
Popular Materials Processed by Wire EDM WEDM
Wire electrical discharge machining allows for the processing of all electrically conductive materials. Mechanical hardness does not affect the ability to machine, which is the main advantage of this technology. The variety of processed materials includes structural steels, tool steels, special alloys, and non-ferrous metals.
The aerospace industry uses titanium alloys due to their excellent strength-to-weight ratio. The automotive sector prefers high-strength steels and cast iron alloys for engine components. The medical field requires biocompatible titanium and surgical steel alloys. Electronics demand precise parts made from copper and conductive alloys.
- Carbon and low-alloy steels with carbon content of 0.1-1.7%
- Tool steels hardened to 60-65 HRC
- Austenitic, ferritic, and martensitic stainless steels
- Titanium alloys Grade 2, Grade 5 for the aerospace industry
- Nickel-based superalloys Inconel, Hastelloy, Waspaloy
- Aluminum alloys 2xxx, 6xxx, 7xxx for lightweight structures
- Non-ferrous metals – copper, brass, bronze, nickel
- Cobalt alloys Stellite for high-temperature applications
- WC-Co cemented carbides with hardness of 1500-2000 HV
- Conductive ceramics Si3N4, SiC for special applications
The electrical properties of the material determine the machining process parameters. Electrical conductivity affects material removal efficiency and surface quality. Materials with high conductivity require modified pulse generator settings.
Popular Parts and Production Components Made Using Wire EDM WEDM
The tooling industry is a primary field of application for WEDM technology. The production of injection molds requires the highest precision and surface smoothness. Metal stamping dies must withstand millions of operating cycles without losing dimensional accuracy. Punches and dies operate under challenging dynamic load conditions.
The automotive industry uses EDM for manufacturing engine components. Fuel injectors contain precise nozzles with hole diameters of 0.1-0.5 mm. Turbocharger parts operate at temperatures exceeding 800°C. Automatic transmission gears require precise tooth profiles.
Industrial components made by WEDM:
- Injection molds – molding cavities, inserts, sliders with tolerances of 0.01 mm
- Stamping dies – tools for shaping sheet metal with complex profiles
- Punches and dies – working elements of presses for plastic forming
- Graphite electrodes – tools for EDM sinking electrical discharge machining
- Precision guides – machine components with high positioning accuracy
- Turbine blades – energy components with aerodynamic profiles
- Medical implants – biocompatible surgical elements
- Electronic components – heat sinks, shields, conductive connectors
The energy sector produces steam and gas turbine blades up to 1500 mm in length. The aerospace industry requires components with extreme reliability and minimal weight. Personalized medicine needs implants tailored to the patient’s anatomy.
Applications of Wire EDM WEDM
The aviation industry demands components with complex aerodynamic shapes and the highest reliability. Aircraft structural elements are made from titanium and aluminum alloys with strict tolerances. Jet engine parts operate under extreme temperature and pressure conditions. Navigation systems contain precise electronic components requiring micrometer accuracy.
The medical field uses WEDM technology to manufacture surgical instruments and implants. Scalpels and surgical scissors require ultra-sharp cutting edges. Orthopedic implants must meet rigorous biocompatibility standards. Dental instruments need precise working elements with complex shapes.
Industrial sectors using WEDM:
- Automotive industry – engine parts, injection systems, transmission components
- Energy sector – turbine blades, generator parts, cooling system components
- Aerospace – structural parts, engine components, navigation systems
- Medical field – surgical instruments, implants, precision prosthetics
- Electronics – heat sinks, electromagnetic shields, conductive connectors
- Tool industry – injection molds, dies, punches for plastic forming
- Defense industry – weapon system components, optical parts
- Food industry – industrial knives, packaging machine parts
The development of Industry 4.0 demands increasingly precise electronic components. Renewable energy requires efficient wind turbines and photovoltaic panel elements. The space industry sets extreme reliability requirements for satellite components.
Fast order fulfillment
CNC Partner stands out in the market thanks to a flexible approach to order execution. The production organization system allows quick preparation of quotes within 2-48 hours. An experienced team of specialists analyzes each order from technological and economic perspectives. An advanced machine park enables simultaneous execution of multiple projects.
Order fulfillment time ranges from 3 to 45 days depending on the complexity and size of the order. Simpler components can be ready within a few business days. Complex projects requiring lengthy machining operations are carried out according to an agreed schedule. The company ensures constant communication with the client and provides updates on work progress.
Fast and secure delivery of completed orders to customers in Poland and the European Union
The CNC Partner logistics system guarantees timely delivery of products throughout the country. Delivery within Poland is completed within a maximum of 48 hours after production ends. Specialized packaging protects precision components from mechanical damage during transport. All shipments are fully insured against damage or loss.
Customers from European Union countries are served through trusted courier companies. For larger contracts, the company provides its own transportation directly to the client’s premises. Shipping documentation is prepared in accordance with international standards. Shipment tracking allows real-time monitoring of delivery status.
Comprehensive technical support and consulting
CNC Partner offers comprehensive technical support at every stage of project execution. Experienced engineers advise on selecting optimal design solutions. Analysis of technical documentation enables identification of potential issues before production begins. Optimization of technological processes ensures the highest quality at competitive costs.
The team of specialists collaborates with design offices in developing prototypes. Services include repair and refurbishment of injection molds and technological tools. Regular employee training ensures familiarity with the latest technologies and quality standards. Investments in modern measuring equipment guarantee quality control at the highest level.
Innovative solutions and technological development
The company systematically invests in modern technologies and equipment. The advanced machine park includes the latest generation of computer-controlled CNC machines. CAD/CAM systems enable designing and programming the most complex geometries. Automation of production processes increases efficiency and repeatability of execution.
Collaboration with scientific research centers allows implementation of innovative solutions. The certified metrology laboratory provides precise control over dimensions and geometric parameters. Continuous quality monitoring of processes guarantees compliance with the highest industry standards. Long-term partnerships with clients build mutual trust and loyalty.
FAQ: Questions and Answers
Most standard WEDM machines can process materials up to 200 mm thick. Advanced industrial systems offer significantly greater cutting capabilities. A modern machine fleet can handle parts exceeding 400 mm in thickness.
Material thickness directly affects machining speed and surface quality. Thin materials are processed faster while maintaining high precision. Thicker components require carefully selected machining parameters. Thermal stability of the machine is essential during prolonged operations.
Modern WEDM machines achieve dimensional tolerances of ±0.002 mm. Precise numerical control ensures repeatability on a micrometric scale. Surface roughness can be reduced below Ra 0.2 µm with proper parameter selection.
Dimensional accuracy depends on several technological factors. Thermal stability of the working environment affects the final dimensions of the part. The quality of the wire electrode determines the smoothness and precision of the cut. Proper machine calibration ensures compliance with the strictest design tolerances. Materials with varying electrical conductivity may require individually adjusted machining parameters.
The wire EDM process is characterized by the absence of mechanical forces acting on the machined part. There is no direct contact between the tool and the material throughout the operation. The machining zone temperature is controlled by the dielectric cooling system.
The elimination of mechanical stress is a key advantage of WEDM technology. Delicate components can be machined without the risk of deformation. Thin walls and complex geometries maintain dimensional stability. The material’s crystal structure remains unchanged during the electrical erosion process.
The most important parameter is the discharge current, which controls the intensity of erosion. Pulse duration determines the size of craters formed on the surface. Operating voltage affects the stability of the electrical arc between the wire and the material. The wire feed rate must be synchronized with the material removal rate.
Dielectric fluid properties play a key role in the machining process. The fluid’s electrical conductivity must be kept within specified limits. Flushing pressure is responsible for removing erosion byproducts from the cutting zone. Operating temperature affects discharge stability and surface quality.
Wire parameters include its diameter, material, and mechanical tension. Thinner wires allow for sharper internal radii. Proper tension prevents vibration and ensures cutting stability.
Preventive maintenance should be carried out according to the equipment manufacturer’s recommendations. Daily tasks include checking the level and cleanliness of the dielectric fluid. Weekly inspections focus on the condition of the wire guides and the tensioning system.
Monthly checks require verification of positioning accuracy and machine calibration. Annual servicing involves a comprehensive inspection of all mechanical and electrical components. Filters for the working fluid should be cleaned regularly, and the hydraulic system should be checked for leaks. Wire guides must be cleaned and lubricated regularly in line with the maintenance schedule.
Wire breakage is the most common operational issue, typically caused by improper mechanical tension. Excessive tension can lead to wire snapping when machining difficult materials. Insufficient dielectric flushing results in the buildup of erosion debris in the cutting gap.
Surface quality issues may arise from contaminated dielectric fluid. Incorrect generator settings can cause surface irregularities. Worn wire can introduce defects on the machined surface.
Loss of dimensional accuracy often stems from thermal deformation of the machine. Improper calibration leads to systematic dimensional errors. Worn wire guides cause vibrations and reduce cutting precision. Regular inspection and maintenance prevent most operational issues and ensure stable production quality.