Suzhou Hanqi CNC Equipment Co., Ltd. is a high-tech enterprise dedicated to researching and producing various high-precision DIE SINKER EDM and WIRE EDM machines, with industry-leading machining accuracy. Welcome domestic and foreign customers to visit our factory to discuss cooperation!
Why Choose Us
Construction Area
The company currently has a modern factory of more than 20 acres in the high-tech zone of Suzhou City, Jiangsu Province, with a construction area of more than 20,000 square meters, more than 80 employees, and engineers account for 30%.
Our Certificate
The company has passed the "ISO9001" quality management system certification, won the national "high-tech enterprise", "provincial private technology enterprise", and is the director unit of "China Machine Tool Industry Association Special Processing Machine Tool Branch".
Our service
24-hour service. The after-sales service in different countries is mainly provided by agents from different countries. If customers need to repair themselves, we can provide relevant spare parts.
Years Of Experience
Engaged in electric machining research and development services for over 20 years. Fully CNC mirror EDM was successfully developed and put into production. Introduce modern enterprise management mode (enhance soft power).
Product Categories
What is Mirror EDM Machine
Mirror EDM machine, also known as Sinker EDM or Conventional EDM, is a specialized form of electrical discharge machining that utilizes a shaped electrode to erode the workpiece. The process involves creating a negative impression or "mirror" of the electrode shape in the workpiece. This technique is widely employed for producing intricate and precise molds, dies, and components, particularly in tool and die manufacturing.
Benefits Mirror EDM Machine
High-precision machining
Mirror EDM machines can achieve high-precision machining, which is achieved by controlling the mold precision with precision machinery. This high-precision machining is particularly important for the precision machining of complex mold cavities and complex curved surfaces, which can save the manual polishing process and improve the performance of parts.
Not Affected by Material Hardness
One of its main benefits is that the efficiency of mirror EDM machine is unaffected by the hardness of the workpiece material. Any material, regardless of its hardness, can be processed using this method.
Tight Tolerances
Mirror EDM machine yields higher levels of accuracy when machining metal than other machining techniques like laser and plasma cutting. Mirror EDM machine can achieve extremely high precision to meet requirements and fit particular dimensions.
Cost savings
Mirror EDM machines are almost unaffected by heat during machining, so they can reduce the heat-affected layer and improve the quality of the workpiece after machining. In addition, since the tool electrode material does not need to be harder than the workpiece material, the tool electrode is easy to manufacture, which reduces production costs.
What Materials can be Used for Mirror EDM Machines?
Stainless Steel
Offers good corrosion resistance along with the ability to achieve a mirror finish.
Tungsten
Extremely hard and wear-resistant, making it ideal for tools and molds that require a polished surface.
Beryllium Copper
Used for its combination of strength, conductivity, and ability to be machined to a fine finish.
Brass
Often used for making EDM electrodes, but can also be machined to a mirror finish.
Titanium and Titanium Alloys
Used in aerospace and medical industries for their high strength-to-weight ratio and biocompatibility, while being capable of achieving a polished finish.
Graphite
Although primarily used as an electrode material in EDM, graphite can also be machined to a very fine finish for certain applications.
Application of Mirror EDM Machine
Industry
In the industry, mirror EDM machines test parts for many different planes and spaceships. Tight deep hole requirements, thin slots, sharply squared holes, and turbine rotor discs are just some problematic features that mirror EDM machine can create.
Power Tool Production
Mirror EDM machine is commonly used to make precision components for power tools and other parts that require intricate shapes or tight tolerances, with applications including drill bits, scissors and valves. Mirror EDM machine also produces a finish that is hard to replicate with other manufacturing processes: Since the electrode leaves no particles behind, it has a smooth surface that resembles glass.
Automotive Industry
Mirror EDM machine is widely used to manufacture automotive parts such as cylinder heads, intake manifolds and intake valves. The main advantage of mirror EDM machine over other methods is that it can produce complex shapes with acceptable tolerances at high speed and low cost.
Precision mold processing
Mirror EDM machine tools can be used to manufacture precision metal molds, such as injection molds, stamping molds, etc. It can accurately etch complex shapes on metal materials, improving the precision and surface quality of molds.
The oil comprises the following raw materials in parts by weight: 6 to 10 parts of solvent oil D110, 0.7 to 1 parts of poly epoxy succinic acid, 2 to 3 parts of dodecyl phenyl succinic acid, 0.1 to 0.14 parts of triallyl isocyanurate, 0.02 to 0.04 parts of 1,2,3 - benzotriazole, 0.1 to 0.2 parts of polyimide, 1 to 2 parts of polyacrylamide, 75 to 85 parts of n-alkanes solvent oil, 0.6 to 1 parts of isopropyl oleate, 1.5 to 2 parts of corrosion inhibitor, 0.05 to 0.06 parts of zinc acetylacetonate, 0.01 to 0.02 parts of polyglycerol fatty acid ester, 2 to 4 parts of N - vinyl pyrrolidone, 0.3 to 0.4 parts of ethyl orthosilicate and 0.1 to 0.2 parts of simethicone. The finished product produced by the invention is high in chemical stability, relatively long in service life, good in environmental protection and outstanding in comprehensive performance.
How to Ensure the Accuracy of the Mirror EDM Machine for a Long Time?
Do not point the mirror EDM machine tools directly at the air vent of the air conditioner, and do not allow direct sunlight to hit it. Therefore you need to adjust the air conditioning equipment.
The electrode used for processing will expand and contract with temperature changes. After rough machining, the electrode is heated in a stretched state. In order to minimize the impact, it is necessary to improve the cooling effect of the electrode and increase the processing liquid level so that the electrode is completely immersed in the processing liquid.
Install the machining fluid cooling device for the mirror EDM machine. After the rough machining of the mirror EDM machine is completed, pause the machining and allow time for the electrode to cool down.
Workpiece Size and Weight Capacity
Determine the maximum size and weight of the workpieces you'll be machining. The machine should be capable of handling the largest and heaviest parts you intend to work with.
Surface Finish Quality
The primary reason for choosing a mirror EDM machine is often the superior surface finish it can achieve. Assess the machine’s capability to produce the desired surface finish without additional polishing.
Automation
Automation can significantly improve efficiency, especially in high-volume production. Advanced control features can also enhance precision and repeatability.
Cooling and Flushing Systems
Effective cooling and flushing are crucial for maintaining accuracy and prolonging machine life, especially during extended machining cycles.
Costs
Balance your budget with the machine’s features, reliability, and efficiency. Investing in a high-quality machine may result in lower long-term costs due to reduced maintenance and increased productivity.
How to Maintain Mirror EDM Machine
Cleaning
Ensure that the machine’s components, such as the worktable, tool holders, and dielectric fluid tank, are cleaned regularly. Remove any debris, carbon deposits, and contaminants that can affect the precision and performance of the machine.
Regularly check
Inspect and maintain electrodes regularly. Ensure they are properly aligned and free from wear or damage. Replace electrodes as needed to maintain the quality of the machining process and to avoid surface defects on the workpiece.
Replacement
Replace the filters in the mirror EDM machine’s dielectric system according to the manufacturer’s guidelines. Clogged or dirty filters can reduce the efficiency of the dielectric fluid, leading to poor machining performance and potential damage to the machine.
Lubrication
Ensure that all moving parts of the mirror EDM machine are adequately lubricated to minimize wear and tear. Regularly inspect and maintain the cooling system to prevent overheating, which can affect machining accuracy and lead to machine downtime.
High precision wire EDM is a type of EDM that uses a wire running continuously through the workpiece to cut complex shapes with tight tolerances and minimal kerf. Throughout the wire cutting process there isn’t any direct contact between the wire and the work piece allowing for machining without causing any deformation in the wires path, or the shape of the material. Blanking punches and extrusion dies are frequently machined via high precision wire EDM cutting.
Benefits of High Precision Wire EDM
Absolute Precision
When it comes to precision, high precision wire EDM is in the upper echelon. The method is capable of achieving accuracy down to the submicron level. This level of precision is essential in industries like medical and aerospace/defense, where even the smallest deviation can lead to catastrophic consequences.
Versatile Material Compatibility
High precision wire EDM is compatible with a wide range of materials, from metals like aluminum, brass, and steel to conductive hard plastics. This versatility makes it a valuable tool in various sectors, including automotive, medical, and aerospace.
Burr-Free Cuts
The high precision wire EDM process produces burr-free cuts, particularly important in industries where sharp edges are problematic. The absence of burrs minimizes the need for our value added services, reducing production time and costs.
Create Intricate and Complex Shapes
High precision wire EDM excels at creating intricate and complex shapes. The method allows for the creation of components with tight tolerances, as well as shapes and paths that would be challenging or impossible to attain with conventional techniques.
How Does High Precision Wire EDM Work?
High precision wire EDM works by creating an electrical discharge between the wire or the electrode and the work piece. As the spark jumps across the gap, material is then removed from the work piece and the electrode. Due to the inherent properties of the process, wire EDM can easily machine complex parts and precision components out of hard conductive materials. To stop the sparking process from shorting out, a non-conductive fluid or dielectric is also used in the process. The waste material is removed by the dielectric, and the process continues.
How Accurate is High Precision Wire EDM ?
The precision of the cuts is one of the standout features of high precision wire EDM, making it a preferred choice for industries such as aerospace and electronics where high accuracy is vital. A typical wire EDM can achieve tolerances of +/- 0.005 mm, although this may vary based on the specific machine and the material being worked on. This high level of precision is possible due to the non-contact nature of the process, which eliminates mechanical stress on the workpiece. The accuracy can vary depending on factors such as the quality of the machine, the material being machined, and the condition of the wire and dielectric fluid.
Sinker EDM vs High Precision Wire EDM Machining Comparison
Method of Operation
Sinker EDM, also known as Ram EDM or Die-Sinker EDM, involves an electrode and workpiece submerged in an insulating liquid like oil or dielectric fluid. The electrode and workpiece do not make physical contact, but a spark is generated through the dielectric fluid, melting and vaporizing a small portion of the workpiece.
Wire EDM, or Wire-Cut EDM, on the other hand, involves a thin wire acting as the electrode. The wire, usually made from brass or stratified copper, is held between two diamond guides and moves in a carefully controlled pattern. As with Sinker EDM, a spark jumps the gap between the wire and the workpiece, but the spark is controlled along the wire path, cutting the workpiece.
Dielectric Liquid
Both Sinker EDM and Wire EDM require the use of a dielectric liquid, which acts as an insulator until the voltage reaches a point where a spark is formed. In Sinker EDM, the workpiece and the electrode are submerged in this dielectric liquid. When the electrical voltage between the electrode and the workpiece overcomes the dielectric fluid’s resistance, a spark jumps across the gap and removes a small piece of the workpiece.
In Wire EDM, the dielectric liquid also cools and lubricates the wire and flushes away the eroded particles. The constant replenishment of fresh dielectric fluid ensures optimal cutting conditions and promotes a higher quality cut.
Applications
Sinker EDM is better suited for creating complex shapes and molds, cavities, or intricate patterns, especially when the material is extremely hard or tough. It is widely used in the aerospace and automotive industries for manufacturing engine components, gears, and turbine blades.
Wire EDM shines when precision and detailing are crucial. The ability to make fine cuts makes it perfect for creating miniature parts, tools, and dies, especially for the electronics and medical industry.
Surface Finish
Sinker EDM usually leaves a textured surface, which might need additional finishing. The surface finish in Sinker EDM depends on the size of the electrode, power settings, and the flushing condition.
In contrast, Wire EDM often provides a better surface finish, as the constantly moving wire electrode minimizes the risk of over-burn, and results in a finer finish.
Aerospace Industry
The aerospace industry requires high precision parts and components, which is why wire EDM is widely used in this sector. This machining is used to create intricate shapes and designs in parts for aircraft engines, landing gear, and other critical components. Aerospace parts often require complex geometries and tight tolerances, which can be achieved through wire machining.
Medical Devices Industry
High precision wire EDM is an indispensable tool in the medical device industry. Medical implants such as pacemakers, stents, and orthopedic implants require precise shapes and dimensions to function properly. The precision of wire machining ensures that these devices are made to exact specifications, which is critical for their success.
Automotive Industry
The automotive industry requires high-precision parts and components for cars, trucks, and other vehicles. High precision wire EDM is used to create molds for plastic injection parts used in manufacturing car interiors and exteriors. These molds require high accuracy and consistency, and EDM is the best tool for the job.
Mold and Die Industry
The mold and die industry relies heavily on wire EDM for the creation of molds and dies for plastic injection molding. It is used to create complex shapes and designs in these molds, which are then used to produce a wide range of plastic parts. The precision and accuracy of high precision wire EDM ensure that the molds and dies are made to exact specifications, which is critical for the success of plastic injection molding.
How Can you Optimize the Efficiency of a High Precision Wire EDM?
Choose the right wire
The wire is the main cutting tool in wire EDM, and its quality and characteristics can affect the speed, accuracy, and surface finish of the machining process. The most common wire materials are brass, copper, zinc-coated brass, and coated wires. You should choose the wire that best suits your machining needs and budget, and replace it regularly to avoid wire breakage, wear, and contamination.
Adjust the cutting parameters
The cutting parameters are the settings that control the electrical discharge between the wire and the workpiece, such as the voltage, current, frequency, pulse duration, and gap distance. These parameters determine the intensity and duration of the sparks that remove the metal material, and thus affect the cutting speed, accuracy, and surface finish. You should adjust the cutting parameters according to the material properties, geometry, and tolerance of the workpiece, as well as the wire type and diameter.
Optimize the flushing system
The flushing system is the mechanism that delivers the dielectric fluid to the cutting zone, where it cools, lubricates, and cleans the wire and the workpiece. The dielectric fluid also acts as an insulator that prevents premature or excessive sparking, and as a conductor that enables controlled sparking when needed. The flushing system is essential for maintaining the stability and quality of the cutting process, as well as preventing overheating, wire breakage, and debris accumulation. You should optimize the flushing system by selecting the appropriate dielectric fluid, ensuring sufficient pressure and flow rate, and positioning the nozzles correctly.
Maintain the machine components
The machine components are the parts that support and move the wire and the workpiece, such as the wire guides, rollers, tensioners, bearings, motors, and controllers. These components are subject to wear and tear, corrosion, and damage from the electrical discharge, the dielectric fluid, and the metal debris. If these components are not properly maintained, they can cause problems such as wire misalignment, vibration, loss of accuracy, and reduced efficiency. You should maintain the machine components by following the manufacturer's instructions, cleaning and lubricating them regularly, and replacing them when necessary.
Monitor the machine performance
The machine performance is the measure of how well the wire EDM machine operates and produces the desired results. The machine performance can be affected by various factors, such as the environmental conditions, the operator's skill, the machine's age, and the machining task's complexity. If the machine performance is not monitored, it can lead to errors, defects, rework, and waste of time and resources. You should monitor the machine performance by using the machine's built-in sensors, indicators, and feedback systems, as well as external tools such as gauges, micrometers, and optical devices.
Precautions for Using High Precision Wire EDM
When using high precision wire EDM, the following points need to be noted in order to obtain ideal processing accuracy: Accurately clamp and position the workpiece before machining to ensure that it will not loosen or shift during machining.
Check the working fluid often. Replace it to keep it stable while using high precision wire EDM. After machining is completed, clean up the workpiece and machine tool in time to remove the residual working fluid and chips.
Reasonable arrangement of machining sequence, first roughing and then finishing. For the complex shape of the workpiece, the use of segmented processing or multiple cutting methods to improve machining accuracy.
FAQ
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