Electrical discharge machining (EDM) is a process of metal

machining in which a tool discharges thousands of sparks to a metal

workpiece. A non-conventional process, EDM works on parts resistant to
conventional machining processes, but only if these parts are electrically
conductive; usually, they are non-ferrous, and include steel, titanium, super
alloys, brass, and many other metals. Instead of cutting the material, EDM
melts or vaporizes it, leaving little debris and providing a very accurate line.
Industry-wide acceptance has led to a wide variety of EDM applications, as
it is highly versatile, can cut hard metals, and utilizes a relatively compact
amount of workspace.
Differences Between Wire Cut and Conventional EDM
There are two main types of EDM: conventional and wire. Conventional
EDM, as described above, uses a tool to disperse the electric current. This
tool, the cathode, runs along the metal piece, the anode, and the electrical
current reacts to melt or vaporize the metal. As a result of the dielectric
fluid, what little debris produced washes away from the piece. Wire cut
EDM (or WCEDM) discharges the electrified current by means of a taut
thin wire, which acts as the cathode and is guided alongside the desired
cutting path, or kerf. A dielectric fluid submerges the wire and workpiece,
filtering and directing the sparks. The thin wire allows precision cuts, with
kerfs as wide as three inches and a positioning accuracy of +/- 0.0002.
This heightened precision allows for complex, three dimensional cuts, and
produces highly accurate punches, dies, and stripper plates.

Wire cut EDM equipment is run by computer numerically controlled (CNC)
instruments, which can control the wire on a three-dimensional axis to
provide greater flexibility. Whereas conventional EDM cannot always
produce tight corners or very intricate patterns, wire EDMs increased
precision allows for intricate patterns and cuts. Additionally, wire EDM is
able to cut metals as thin as 0.004. At a certain thickness, wire EDM will
simply cause the metal to evaporate, thereby eliminating potential debris.
The wire of a WCEDM unit emits sparks on all sides, which means the cut
must be thicker than the wire itself. In other words, because the wire is
surrounded by a ring of current, the smallest and most precise cutting path
possible is the added diameter of the ring and wire; technicians easily
account for this added dimension. Manufacturers continue to produce
thinner and thinner wires to allow for smaller kerfs and even finer
precision.
Wire Cut EDM Applications
Because of its versatility, manufacturers us wire cut EDM functions for an
extensive range of applications. Because the process can cut very small
pieces, it is often an ideal choice for the production of small, highly detailed
items that would normally be too delicate for other machining options.
Additionally, the process is cost effective for low quantity projects, and can
prove to be beneficial in prototype manufacturing, even if the actual project
is carried out by different means.

It is important to remember that the wire in the process is constantly
moving, and not to be reused. As a result, the copper, brass or other
metallic wire can be kilometers long, adding to the cost. And, while the
process uses no force and thus does not cause burrs and can be used on
delicate items, the possibility of thermal stress is certainly present.