Wire EDM Services | Complex CNC Machining for Wire EDM
Wire EDM uses a thin, electrically charged wire to cut intricate shapes in conductive materials. The process erodes material through controlled electrical sparks while everything’s submerged in dielectric fluid, so there’s no mechanical force causing warping or distortion. We can machine hardened tool steel, titanium, Inconel, carbide, and other tough alloys down to tolerances of ±0.0001 inches, with burr-free surfaces that come out clean.
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What is Wire EDM and How does it Work?
Wire EDM removes material through spark erosion between a continuously fed brass or copper electrode and the electrically conductive workpiece. The metal wire, ranging from 0.02 mm to 0.3 mm diameter, passes through the material submerged in deionized water that controls spark formation, cools the cutting zone, and flushes eroded particles. Each electrical discharge melts and vaporizes microscopic material amounts, creating a kerf typically 0.15 mm to 0.4 mm wide.
CNC Programming and Computer-Controlled Precision
The process operates through CNC programming that guides the wire along programmed paths with precision exceeding traditional manufacturing methods. We integrate CAD/CAM software including SolidWorks and KeyCreator for complex contour generation. Unlike conventional cutting tools that exert mechanical force, this non-contact EDM machining services approach eliminates tool wear and workpiece deflection.
Post-Heat Treatment Capability
We machine components after heat treatment, maintaining dimensional accuracy because the thermal process adds no mechanical stress to hardened materials. This proves essential for tool steels at HRC 60-65, carbide cutting tools, aerospace alloys requiring dimensional stability, and precision mold components.
Our Wire EDM Machining Services
We provide multi-axis wire cut services from prototype development through high-volume production runs using advanced computer-controlled systems. Our EDM wire cutting capabilities include 2-axis through 5-axis machining for three-dimensional contours, taper angles to 30 degrees, and simultaneous upper-lower independent contouring. We cut workpieces up to 400 mm thick with 600 mm × 400 mm XY travel.
Service Capabilities
| Тип услуги | Толерантность | Приложения |
|---|---|---|
| High Precision Engineering | +/- 0.0001 inch (2.5 micron) | Aerospace, medical implants, surgical instruments |
| Prototype to One-Off | Single parts to 50 pieces | Design validation, functional testing |
| Full Production Runs | 100 to 10,000+ volumes | Injection molds, progressive dies, punches and dies |
| Микрообработка | Wire 0.02-0.3 mm | Keyways, splines, gear profiles, intricate patterns |
Wire Electrode and Machine Options
Our electrode selection includes standard brass wire for general applications, zinc-coated brass for improved speed, copper wire for specialized requirements, and fine wire (0.02-0.1 mm) for micro-detail work. Automated wire threading enables lights-out manufacturing for extended production with minimal operator intervention.
Which Materials Can Wire Cut Through Metal Effectively?
We machine conductive материалы including ferrous and non-ferrous metals, hardened alloys, and exotic materials resisting conventional manufacturing methods. Wire EDM cuts tool стали (D2, A2, O1, H13), stainless steels (304, 316, 17-4 PH), high-speed steels (M2, M4), and pre-hardened steels without deflection. The process excels with Inconel 718, Hastelloy X, титан alloys (Ti-6Al-4V), tungsten carbide, алюминий, graphite, and molybdenum causing rapid tool wear in traditional Фрезерование с ЧПУ operations.
Material Categories
Tool and Die Steels:
- Progressive dies, stamping punch components, ejector pins
- Fine blanking tooling, matched metal tooling
- D2, A2, O1, S7, H13 variants
High-Performance Alloys:
- Turbine blades, combustion chambers (Inconel, Hastelloy)
- Aerospace structural components (titanium alloys)
- Chemical processing equipment (Monel, Hastelloy C-276)
Carbide and Hard Materials:
- Cutting tool inserts, wear-resistant precision components
- Forming dies, extrusion dies, custom shapes
- Tungsten carbide, ferro-titanium carbide, CPM 10V
Medical and Specialty Materials:
- Medical implants and surgical instruments (titanium, cobalt-chrome)
- Food processing equipment (316L stainless steel)
- Dental device components
Material hardness does not affect cutting speed in wire electrical discharge machining, unlike conventional machining, where harder materials require slower feed rates. We machine heat-treated components at full hardness (HRC 60+), eliminating dimensional changes from post-machining heat treatment.
Why Choose Wire Cutting Services Over Conventional Methods?
Wirecutting eliminates mechanical cutting forces, enabling distortion-free machining of thin-walled sections and delicate features. Conventional milling exerts forces that deflect thin walls and require substantial clamping. Wire EDM’s spark erosion applies zero mechanical force, cutting 0.5 mm thick webs without deflection.
Key Manufacturing Advantages
Surface Quality:
- Отделка поверхности from 0.4 μm Ra to 1.6 μm Ra
- Sharp internal corners with radii matching wire diameter (0.01-0.15 mm)
- Eliminates deburring and finishing labor
Complex Geometry:
- Stack cutting multiple identical parts simultaneously
- Sharp-cornered pockets and narrow slots (0.1 mm wide)
- Vertical and angled cuts to 30 degrees
- Cross-holes without tool breakage
Production Efficiency:
- No tool wear cost or replacement downtime
- Consistent quality across 10 to 10,000+ piece runs
- State-of-the-art machinery enables 24-hour operation
What Technical Specifications Define Our Capabilities?
Our EDM machines achieve positioning accuracy of +/- 0.002 mm, with repeatability to +/- 0.001 mm. We maintain cutting tolerances within +/- 0.0001 inches (2.5 microns) for aerospace and medical applications, with standard tolerances of +/- 0.0002 inches for general manufacturing.
Machine Specifications
| Параметр | Технические характеристики | Приложение |
|---|---|---|
| Wire Diameter | 0.02-0.3 mm | Fine details to speed cutting |
| Maximum Taper | 30 degrees ±0.05° | Independent upper/lower contouring |
| Workpiece Thickness | Up to 400 mm | Submerged cutting for stability |
| Отделка поверхности | 0.4-1.6 μm Ra | No additional finishing required |
Dielectric System and Process Control
Our filtration systems maintain deionized water resistivity above 200 kΩ·cm for stable spark formation. Automated tensioning adjusts electrode tension from 5 N to 15 N based on diameter and conditions, preventing breakage during precise operations. Machines feature automatic threading that resumes cutting after interruptions.
Related In-House EDM Services
We provide complementary capabilities:
- Sinker EDM: Creates blind cavities using shaped electrodes
- Small-Hole EDM: Drill precision holes from 0.3-3 mm diameter
- Deep-Hole Drilling: EDM drilling for cooling channels
How does Our Quality Assurance Achieve Precision?
We inspect components using coordinate measuring machines (CMM) with +/- 0.0001 inch accuracy, verifying dimensional conformance to engineering drawings and GD&T specifications. Every production run includes first-article inspection, in-process quality checks, and final documentation.
ISO-Certified Quality Management
Our ISO 9001:2015 certified system ensures traceability from raw material certification through final inspection. Statistical process control (SPC) monitoring tracks critical dimensions across batches. For medical device components requiring ISO 13485:2016 compliance, we implement enhanced documentation and validation protocols.
Inspection Methods
- CMM inspection with 3D CAD model comparison
- Optical comparator verification for profile accuracy
- Surface roughness measurement using profilometers
- Проверка сертификации материалов
- Dimensional inspection reports with full GD&T analysis
Design and Manufacturing Support
We provide design for manufacturability consultation before production, identifying opportunities to optimize part geometry for wire cutting allows us to reduce costs. This front-end engineering eliminates unnecessary tight tolerances, recommends appropriate corner radii, and suggests feature modifications improving cutting efficiency.
Why Choose Yijin Hardware for Your Wire EDM Project?
We combine wire EDM precision with comprehensive CNC machining capabilities including milling, поворот, grinding, and surface finishing. This integrated approach eliminates multiple vendors, reduces lead times, and ensures consistent quality across complex assemblies. Our engineering team provides DFM analysis, material selection guidance, and manufacturing optimization, reducing per-part costs.
With multiple systems operating continuously, we accommodate rush orders, high-volume production, and complex projects. Our expertise across aerospace tooling, medical device manufacturing, automotive dies, and precision mold components gives us industry-specific knowledge of material certifications, inspection protocols, and documentation standards. We deliver prototype parts in 5-7 days and production volumes with lead times scaled to project complexity.
Что говорят наши клиенты
Wire EDM Services FAQs
Wire EDM manufactures components requiring intricate internal contours, sharp corners, or precise tolerances in hardened materials where conventional machining proves ineffective. Common applications include progressive stamping dies with complex punch profiles, injection mold cavities with sharp-cornered cooling channels, and aerospace turbine blade fir-tree roots. The technology also produces extrusion dies, fine blanking tooling, precision gauges, and medical implant components from titanium or cobalt-chrome alloys.
Wire EDM uses a thin traveling wire electrode to cut through entire workpiece thickness, creating two-dimensional profiles and three-dimensional contours. Sinker EDM uses a shaped electrode that plunges into the workpiece to create cavities and blind pockets. Wire EDM requires cutting through material thickness and cannot create blind features, while sinker EDM machines internal cavities without through-cuts but requires custom electrode manufacturing.
Deionized water used as dielectric fluid requires continuous filtration rather than complete replacement, with filter cartridges changed every 200-400 machine hours depending on material type. The filtration system removes metal particles while maintaining water resistivity above 200 kΩ·cm for proper spark formation. Complete fluid changes occur annually or when resistivity cannot be maintained through filtration alone.
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