Wire Electrical Discharge Machining (Wire EDM), also known as wire cutting, is a precision non-traditional machining process that uses a thin metal wire (typically brass or copper) as the electrode to remove material from the workpiece through successive electrical discharges. The process occurs in a dielectric fluid environment, which cools the workpiece, flushes away debris, and maintains the stability of the electrical discharge. Unlike conventional machining, Wire EDM does not require direct contact between the tool and the workpiece, enabling high-precision processing of complex shapes without causing mechanical stress or deformation to the material.

Core Advantages of Bomei’s Wire EDM Machining Service

• Exceptional Precision & Tight Tolerances: Achieves standard tolerances of ±0.001 mm, with capabilities down to ±0.0005 mm for high-precision requirements, ensuring consistent dimensional accuracy for complex components.
• No Mechanical Stress on Workpieces: Non-contact machining eliminates tool wear and avoids applying pressure to the workpiece, making it ideal for processing brittle, hard, or thin-walled parts that are prone to deformation.
• Superior Surface Finish: Delivers smooth surface finishes with Ra values ranging from 0.2 μm to 1.2 μm, reducing the need for additional post-processing and improving the aesthetic and functional performance of parts.
• Capability for Complex Geometries: Easily processes intricate shapes such as micro-slots, narrow gaps, complex contours, and internal cavities that are difficult or impossible to achieve with conventional milling or turning processes.
• High Processing Stability: Equipped with advanced CNC control systems and intelligent dielectric fluid circulation systems, ensuring stable machining performance even during long-duration production runs.

Applicable Materials for Wire EDM Machining

1. Hardened Metals & Alloys

2. Precious Metals

3. Other Conductive Materials

Aluminum alloys, copper alloys (brass, bronze), and conductive composite materials, adapting to diverse industry material requirements.

Types of EDM Cutting Processes

• Die sinking EDM

The die sinking EDM process is the conventional electric discharge machining process. Die sinking EDM uses a die to create complex features. Die sinking EDM involves the use of a die, which is an electrode made out of copper or graphite and is used to shape the metal. An electric current is passed through the die to erode the metal away in a controlled manner. The die is then gradually moved in order to create the desired shape while the material excess is flushed away in the dielectric fluid. This process is particularly useful for machining complex shapes that are difficult to create using conventional machining techniques and other EDM methods.

• Wire cut EDM

Something like a wire cutting through cheese, the wire EDM machining process relies on a thin wire that cuts through metal via spark erosion. Wire EDM works by using a thin wire to create sparks between the wire and the material being cut. The sparks erode the material and create a precise cut. This process can be used to cut complex shapes and intricate patterns. In many cases wire EDM is faster and more accurate than traditional machining methods, making it cost-effective for certain shapes. When two axis of motion are involved it results in parts with vertical edges and two-dimensional shapes. EDM wire cutting machines are capable of creating complex shapes with incredibly tight tolerances. Materials that can be cut by wire EDM include all conductive metals such as titanium, steel, aluminum, and brass.

• Hole drilling EDM

Hole drilling EDM is a machining process that uses electrical discharges to create holes in metals. The process is similar to conventional drilling, but instead of using a drill bit, an electrode is used to create sparks between the workpiece and electrode. The spark discharges melt or vaporize tiny amounts of the workpiece, which can then be further machined to the required size and shape. Hole drilling EDM is an extremely accurate and precise method of machining and can be used to create holes in very hard materials. Hole drilling EDM can create small and deep cavities in materials.

Industry Applications of Wire EDM Machining

• Aerospace: Processing of turbine blades, engine components, aerospace fasteners, and precision structural parts made of high-temperature alloys.
• Medical Devices: Manufacturing of surgical tools, orthopedic implants, medical instrument components, and micro-parts requiring biocompatible materials and high precision.
• Mold & Die Industry: Machining of mold cavities, cores, ejector pins, and precision die components, especially for hardened steel molds.
• Electronic & Electrical: Production of micro-electronic components, connector pins, sensor parts, and precision motor components.
• Automotive: Processing of high-precision automotive parts such as fuel injection nozzles, transmission components, and brake system parts.