Expert knowledge paired with experience are elementary basic requirements so that the works produced with wire EDM can be manufactured with high precision and economically. Here is an overview of some important advantages of wire EDM.
Advantages of wire EDM
Compared to laser cutting and waterjet cutting, wire EDM is unmatched. Even with a rough cut, the tolerances are in the hundredths range. With appropriate recuts, accuracies of a few thousandths of a millimetre can be achieved with absolute process reliability.
Mechanical processes such as milling or turning do not produce fine surfaces easily. The surface roughness of direct cutting with wire EDM is already clearly in the finishing range with Ra 2.8. Up to Ra 0.4 is standard for wire EDM.
A sawing gap takes away about 2 to 3mm of material and is relatively inaccurate. The fine EDM wire with diameters of 0.05 to 0.3 millimetres produces very narrow cutting widths and thus also enables filigree contours.
Wire EDM was first used in punching tool manufacturing and enabled sharp die corners where it was usually necessary to file them by hand. This is one of the great advantages also in mould making, where narrow flat and mould ejector apertures are cut.
Even in high workpieces of up to 400mm, broaches and parting cuts can be eroded without any problems.
Laser cutting achieves high cutting speeds, but only one part at a time can be machined. With wire erosion, thin workpieces can be cut in stacks, which greatly reduces the cutting time per workpiece.
In contrast to mechanical machining, wire erosion does not generate any surface stresses. Therefore, even very filigree geometries are wire-eroded from the solid, practically free of distortion.