WIRE CUT EDM

Electrical discharge machining (EDM), sometimes colloquially also referred to as spark

machining, spark eroding, burning, die sinking, wire burning or wire erosion, is a
manufacturing process whereby a desired shape is obtained by using electrical discharges
(sparks).[1] Material is removed from the workpiece by a series of rapidly recurring current discharges
between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of
the electrodes is called the tool-electrode, or simply the "tool" or "electrode", while the other is called
the workpiece-electrode, or "workpiece". The process depends upon the tool and workpiece not
making actual contact.
When the voltage between the two electrodes is increased, the intensity of the electric field in the
volume between the electrodes becomes greater than the strength of the dielectric (at least in some
places), which breaks down, allowing current to flow between the two electrodes. This phenomenon
is the same as the breakdown of a capacitor (condenser) (see also breakdown voltage). As a result,
material is removed from both electrodes. Once the current stops (or is stopped, depending on the
type of generator), new liquid dielectric is usually conveyed into the inter-electrode volume, enabling
the solid particles (debris) to be carried away and the insulating properties of the dielectric to be
restored. Adding new liquid dielectric in the inter-electrode volume is commonly referred to as
"flushing". Also, after a current flow, the difference of potential between the electrodes is restored to
what it was before the breakdown, so that a new liquid dielectric breakdown can occur.
Three basic conditions that wire cut EDM work correctly:

1. The gap between electrode wire and workpiece should be certainly maintained in a
required range. Within this range, not only impulse power can break through insulating
liquid to create spark discharging, but also the eroded workpiece can be flushed away
after discharging process. If gap is too big, insulating liquid can’t be break through,, and
there will be no spark discharging; if gap is too small, short circuit is easy to happen, no
spark discharging neither.

2. The procedure should happen in the liquid with insulate capacity, for example
saponification and deionized water, the liquid could act as medium of discharging
channel and provide cooling and flushing.

3. Electrical discharging should be short time impulse discharging,. As with short

discharging time, the released heat won’t affect inside material of workpiece, and limits
energy to a tiny field and keep characteristics of cool machining of wire cut EDM
machine.

MAJOR COMPONENTS
A Wire EDM system is comprised of four major components.
(1) Computerized Numerical Control (CNC)
Think of this as “The Brains.”
(2) Power Supply
Provides energy to the spark.
Think of this as “The Muscle.”
(3) Mechanical Section
Worktable, workstand, taper unit, and wire drive mechanism.
(This is the actual machine tool.)
Think of this as “The Body.”
(4) Dielectric System
The water reservoir where filtration, condition of the water (resistivity/conductivity)
and temperature of the water is provided and maintained.
Think of this as “The Nourishment.”
DIELECTRIC SYSTEM
Wire EDM uses deionized water as the dielectric compared to Vertical EDM’s that
use oil. The dielectric system includes the water reservoir, filtration system, deionization
system, and water chiller unit. During cutting, the dirty water is drained into the unfiltered
side of the dielectric reservoir where the water is then pumped and filtered through a paper
filter, and returned to the clean side of the dielectric tank.
Following filtration, the clean water is measured for conductivity, and if required
passes through a vessel that contains a mixed bed of anion and cation beads. This mixed bed
resin (the ion exchange unit) controls the resistivity of the water to set values automatically.
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The clean water fills the clean side of the dielectric reservoir and proceeds to the
cutting area. Used water is drained and returned to the unfiltered side of the dielectric
reservoir to complete the cycle. A water chiller is provided as standard equipment to keep
the dielectric, workpiece, worktable, control arms, and fixtures thermally stable.
During the cutting process the chips from the material that is being eroded, gradually
changes the water conductivity level. Resistivity levels of the water are set according to the
cutting requirements of the workpiece material being machined.

Submerged Machining
Submerged machining is extremely useful for applications that generally have poor
flushing conditions. Some applications and examples where submerged machining is more
practical would be cutting large taper angles, tall workpieces, laminations, tubes, irregular
shaped parts, workpieces with undercuts and cutting very close to the edge of the workpiece.
Applications where poor flushing conditions exist are numerous. The following examples
might exist on any given job.

STARTING A CUT FROM THE EDGE OF A WORKPIECE

When starting a cut from the edge of a workpiece, cutting a form tool, slicing a tube
or bar stock, or starting a cut from a large diameter start hole, is a slower process without
submerged machining capabilities. There is a greater risk of breaking a wire if the flush is
not set properly or if too much power is used. This condition is greatly reduced when cutting
the part submerged.