AIXI Wire EDM Services

AIXI – Expert in wire cutting, with decades of experience in CNC wire cutting, has provided thousands of EDM manufacturing precision parts for various industries. We have the most advanced and numerous types of wire-cutting equipment, providing precise processing services for various conductive materials. The minimum tolerance of our equipment can be 0.002mm, which provides a guarantee for high-precision instrument parts. AIXI has rich experience in wire cutting and unique and professional insights into CNC processing services. In the precision manufacturing industry, it is often the combination of EDM and CNC that can produce more perfect parts. If you have similar product processing needs, please contact us by email.

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What is Wire EDM Machining?

Wire EDM is a machining method for metal parts, which is essentially a non-contact subtractive manufacturing process. Wire cutting is the process of cutting metal parts into different shapes by generating a short high temperature with a charged thin wire. Therefore, these parts must be made of conductive materials. This processing method is usually combined with CNC Turning, Milling, Drilling, and other processing methods to manufacture parts and is widely used in the processing and manufacturing industry.

Wire cutting cuts parts with a thin wire, so the processed area often presents a right angle. However, if it is machined by a CNC tool, the processed path will form a rounded corner. Therefore, we can choose different processing methods to complete the parts for different needs.

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What is Wire EDM Machining - AIXI

How Does Wire EDM Work?

Wire EDM mainly cuts metal through the processing principle of discharge. The wire-cutting equipment contains a pair of electrodes; one electrode is connected to the fine wire, and the other end is connected to the product. During processing, we immerse the metal part in the dielectric fluid, fix it with a mechanical vise, and then pass the fine wire through the metal. When the equipment is connected to the high-frequency pulse power supply, a very high voltage will be between the tool electrode and the part. Once the two are in contact, an electric spark will be generated, and in this process, the metal surface will be melted to achieve the purpose of product processing.

The dielectric fluid (deionized water) will wash away the molten metal surface fragments from the spark gap. Deionized water can also cool the process and make the part’s surface smoother.

Watch the video to experience the wire EDM process more clearly and intuitively. AIXI can perform high-precision cutting on various conductive materials. Contact us now, and our CNC wire EDM experts will find the right processing solution for you.

Materials for EDM wire cutting

We can usually choose wires of different diameters for EDM metal cutting according to the parts’ size, thickness, and shape. The diameter of the wire for wire cutting is generally between 0.05 and 0.3mm. Different wires will directly affect the precision of the product when cutting. AIXI will choose the appropriate wire processing according to the part’s material and the required tolerance. Watch the video to learn more about Materials for EDM wire cutting.

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Tungsten-Wire

Tungsten wire
Tungsten is a very common material in wire cutting. It is often used to cut molds, heat-treated high-hardness parts, and products with high precision tolerances. Tungsten wire also has high electrical conductivity, which can effectively conduct current in EDM. It also has a high melting point, is oxidation resistant, and has good electrical conductivity.

EDM-wire-cutting-brass-wire

Brass wire
Brass is a common metal with excellent electrical conductivity, so it’s the most favored material for EDM wire cutting. Brass wire can withstand greater contact pressure, it is usually used on thicker parts. Brass has a higher zinc content, so the cutting speed will be faster. Therefore, for thicker parts, better cutting speed can save processing time.

EDM-wire-cutting-Galvanized-steel-wire

Galvanized steel wire
Steel wire, commonly used for cutting steel plates, is suitable for processing that only cuts the shape and has no requirements for tolerances. It is often the first step of CNC machining. By cutting the steel wire, we can get the general shape of a product and then use CNC for precision machining, which can reduce CNC machining time and save costs.

Advantages of Wire Electrical Discharge Machining

  • Fast production speed: Wire EDM has a shorter program setup time and faster EDM processing speed than CNC programming. For prototypes and large-scale production, wire cutting is generally faster.
  • Cost control: Wire cutting can be done using different fine wires according to the different workpiece materials and precision levels, resulting in different processing costs.
  • High processing accuracy: Wire cutting is carried out by melting the metal surface without moving or cutting it, so the processing stability is very high. However, the diameter of the EDM wire can be as low as 0.01 mm, so it can achieve extremely high accuracy and precise cutting.
  • Efficient: Metal plates can be stacked, and multiple products can be cut at once, saving processing time and cost.
  • Suitable for processing complex parts: Complex designs that CNC cannot process can be easily solved using EDM. Therefore, we often combine CNC machining and wire EDM to complete the processing of complex parts.

EDM Wire cutting also has some shortcomings. It can only process products with conductive materials; most materials will form an oxide layer after cutting. Therefore, polishing or CNC finishing is required, which will cause additional costs. You can also watch our video to understand the difference between wire EDM and traditional EDM. AIXI will design the most competitive processing method for you according to the specific use of your product.

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Applications of Wire EDM Machining

Wire cutting is used in many industries because of its unique processing characteristics and is suitable for prototypes and mass production of parts.

Aerospace and automotive industry

The design of parts in the aerospace and automotive industries is usually complex, and most materials have high hardness. The tool will wear badly if we use CNC machining, and some dimensions cannot be fully processed. Therefore, such industries prefer EDM wire cutting, which is suitable for manufacturing holes and cavity parts.

Medical industry

EDM wire cutting is widely used in medical equipment manufacturing. Most common surgical instruments, especially those used in dental implants, use EDM technology. Because the size they require is very small, EDM is very suitable.

Manufacturing-industry

Manufacturing industry (injection molding, stamping molds)

Wire-cutting discharge machining is widely used in mold manufacturing. EDM is required to complete the important parts of common injection and stamping molds.

applications-of-Wire-Electrical-Discharge-Machining | Wire EDM Machining parts

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