What materials can be cut with wire EDM?
Wire EDM can machine any electrically conductive material. This includes all metals, from aluminum and copper to hardened tool steels (like D2, A2, M2), stainless steels, titanium, Inconel, and even conductive ceramics like tungsten carbide. The hardness of the material does not affect the cutting speed or capability, which is a primary advantage of the process.
What are the size limitations for wire EDM parts?
Limits are defined by a machine’s travel (X and Y axis) and its maximum workpiece thickness (Z axis). Standard industrial machines commonly handle parts up to approximately 16 inches thick with travels of 20 inches by 30 inches or more. For larger parts, some providers offer “traveling wire” machines where the workpiece is stationary and the wire guides move. It’s always best to consult with your service provider about your specific part dimensions.
How fine of a detail can wire EDM achieve?
Detail is a function of the wire diameter and machine precision. Standard wire sizes range from 0.010″ down to 0.004″ for fine-wire EDM. Using smaller wire allows for incredibly small internal corner radii, extremely narrow slots, and the machining of micro-sized components. The trade-off is that cutting with finer wire is generally slower than with larger diameters.
Does wire EDM leave a burr?
One of the hallmark benefits of wire EDM is that it typically produces burr-free edges. Because material is removed by vaporization and flushing, rather than shearing, there is no plastic deformation to form a burr. The resulting edge is sharp and clean, often eliminating the need for a deburring operation.
What is the typical surface finish from wire EDM?
Surface finish is measured in microinches Ra (average roughness). Wire EDM can produce finishes in the range of 10-30 Ra routinely, with the potential for even finer finishes using multiple skim cuts. This is often smoother than a standard milled finish and is suitable for many applications without further polishing. The finish has a characteristic matte, spark-eroded appearance.
Can wire EDM cut tapers or shapes that are not vertical?
Yes. Modern 4-axis wire EDM machines can cut with controlled tapers, typically up to 30 degrees or more depending on the material thickness. This allows for the creation of molds with draft angles, punches with relief, and complex 3D shapes like turbine blades directly from a solid block, without the need for multiple setups or secondary operations.
Is wire EDM suitable for prototyping and one-off parts?
Absolutely. The fact that wire EDM requires no custom tooling or fixtures makes it exceptionally well-suited for prototypes and low-volume production. A part can go directly from a CAD file to a finished component quickly. This allows for rapid iteration and testing of complex geometries in the final production material, even if it’s hardened.
How does automation impact wire EDM production?
Automation is a game-changer for production volumes. Features like Automatic Wire Threading (AWT) allow a machine to re-thread itself after a wire break and continue cutting unattended. When combined with pallet changers or robotic part loaders, machines can run “lights-out” for extended periods. This dramatically increases throughput, consistency, and cost-effectiveness for medium to high-volume orders.
What file format do I need to provide for a wire EDM quote?
Most wire EDM services prefer 2D CAD files in formats like DXF or DWG, as the cutting path is primarily two-dimensional. A detailed drawing with tolerances, material specifications, and quantity is also essential. For complex 3D shapes or tapers, a 3D model (STEP, IGES, SLDPRT) may be required. Always confirm with your chosen provider for their specific requirements.