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 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.
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".
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).
Advanced processing database, with only input of processing materials, types, areas, roughness, depth, etc., can achieve efficient, low loss, and accurate VDI processing of graphite steel, red copper aluminum.
Mirror EDM machine is an exceptionally precise process that is ideal for forming complex and intricate shapes and is capable of shaping hard metals such as titanium.
Mirror EDM Machine with Lifting Liquid Tank
The mirror EDM machine with lifting liquid tank process, an alternative to sinker EDM machining, works much like a wood band saw using a wire for the cutting process.
The extreme temperatures of the CNC single head EDM machine process rapidly removes excess material from the workpiece by vaporization and melting or spark erosion.
CNC Single Head EDM Machine Single Head EDM Machine
Advanced processing database, simply input "processing material, type, area, roughness, depth, etc." to achieve efficient, low loss, and accurate VDI processing of.
The CNC double head EDM machine process, an alternative to sinker EDM machining, works much like a wood band saw using a wire for the cutting process.
The wire, made of copper or brass, has a high voltage electrical discharge passed through it that makes it possible for the wire to cut through the thickness of the workpiece.
The wire in CNC single axis EDM machine creates a spark in deionized water where conductivity is precision controlled.
Single axis EDM machine uses a single axis (Z-axis) with auto-feeding control system (including servo feed system and parameters control system), other axes are manual control axis (X-axis and Y-axis).
What is Wire EDM Cutter
Wire EDM cutter is an electro thermal production process where a thin single strand metal wire, along with de-ionised water (used to conduct electricity) allows the wire to cut through metal by the use of heat from electrical sparks, while preventing rust. This process is particularly useful for cutting precisely through conductive materials that are both hard and thick, with some machines able to cut materials over 300mm thick.
Benefits of Wire EDM Cutter
Allows for the Formation of Complex Parts
The use of precisely focused electrical discharges makes it possible to make complex or intricate shapes and patterns. Wire EDM cutters can make different shapes, such as contours and holes, even on the hardest and the most fragile materials.
It Doesn't Need Mechanical Force
Unlike a vast array of fabrication processes that use impact to cut through materials, Wire EDM cutters leverages thermal discharges to cut through parts. This means that the end product will not be deformed, distorted, or have any side effects of deformation caused by brute force in material removal.
Cost-Effectiveness
When you use wire EDM cutters , you'll not have to use a lot of energy to cut even the most rigid materials. Additionally, you'll reduce material wastage since the process only removes the targeted particles only. Your cutting kerf (cut width) is usually less then 0.015". Also, you don't need other machines for post-processing since the method delivers precise and accurate cuts.
Accuracy and Precision
The best part about wire EDM cutters is that your final product will not need to be passed through other processes for them to be complete such as grinding, honing etc. The method delivers high levels of accuracy and precision, especially on the smallest pieces.
High Tolerance
The other benefit of wire EDM cutters is the fact that you can achieve high tolerance regardless of the material you're working on. You can easily achieve tolerance of +/- 0.0005" with some machines that offer tolerances down to a few microns.
How the Wire EDM Cutter Works
Wire EDM cutter process follows the same principle as electrical discharge machining. The wire EDM cutter involves using a brass wire with a current and high voltage that passes through the workpiece. While the workpiece remains fixed, the cut is guided by the moving wire which produces electric sparks when it gets close enough to the grounded workpiece.
In other words, there's a very high voltage between the tool electrode and the part and upon getting in contact, the circuit completes generating an electric spark melting tiny bits of metal in the process. The voltage for wire EDM cutter is so high, that the tool electrode (wire) never touches the metal and the charge jumps to the earthed part. The wire EDM cutters happens in dielectric fluid which controls the spread of the charge and flushes the eroded metal bits away from the spark gap.
How Fast Does Wire EDM Cutter?
On average, wire EDM cutter cut at a rate of about 0.004 to 0.012 inches per minute. The cutting speed of wire EDM cutter varies based on the type of material, thickness, and desired surface finish. Furthermore, speed can be influenced by factors such as the type of wire used, the power settings of the machine, and the conductivity and hardness of the material being cut. While not as fast as some traditional machining processes, wire EDM cutter offers unparalleled precision, making it ideal for complex and detailed work where accuracy is more critical than speed.
What Materials Can Be Processed with Wire EDM Cutter?
Stainless Steel: All grades including 304, 316, 410, 17-4PH. Used for medical parts, aerospace components, molds.
Tool Steel: H13, P20, A2, D2. For tools, dies, mold cavities, and prototypes.
Titanium: Grade 2, 5, 23. Biomedical implants, aerospace hydraulic assemblies.
Inconel: For heat-resistant aerospace engine parts and rings.
Carbides: Tungsten carbide for cutting tools and wear parts.
Copper Alloys: Beryllium copper for electrical contacts and leadframes.
Graphite: For electrodes and mold fabrication.
Aerospace Industry: Wire EDM cutters are used to create complex and precise components like turbine blades, engine parts, and intricate structural components that require high accuracy and fine tolerances.
Medical Device Manufacturing: In the medical industry, wire EDM cutters is employed to produce precise components for medical devices such as surgical instruments, implants, and other specialized medical equipment.
Automotive Industry
Wire EDM cutters is widely used for creating precise components for engines, transmission systems, and intricate parts for fuel injection systems, ensuring they meet exact specifications.
Tool and Die Making
Wire EDM cutters is crucial in the tool and die industry for manufacturing precise molds, dies, and punches used in stamping and injection molding processes.
Electronics Industry
The electronics industry utilizes wire EDM cutters for the production of small, intricate components like connectors, housings, and frames used in various electronic devices.
What Types of Wire Are Used in Wire EDM Cutter?
Brass Wire
The most common choice due to its excellent electrical conductivity and good balance between cost and performance. Ideal for general-purpose machining.
Coated Wire
These wires are typically brass or copper cores coated with a thin layer of another metal, such as zinc. Coated wires enhance cutting speed and improve surface finish, making them suitable for precision applications.
Tungsten Wire
Chosen for its high melting point and strength, tungsten wire is excellent for machining tough, high-temperature alloys. It's particularly useful in applications requiring extremely fine finishes.
Molybdenum Wire
Known for its resistance to heat and excellent electrical properties, molybdenum wire is used in applications that require very high precision and minimal thermal distortion.
Components of Wire EDM Cutter
Workpiece: The material being machined. It must be electrically conductive for the EDM process to work.
Wire Electrode: A thin, electrically charged wire that acts as the cutting tool. Typically made of brass, copper, or coated with other conductive materials.
Power Supply: Generates the electrical pulses that create sparks between the wire and the workpiece.
Dielectric Fluid System: The fluid (often deionized water) surrounds the wire and workpiece.
Worktable: The workpiece is mounted on the worktable, which moves in the X and Y directions.
CNC Controller: A computer-based system that controls the movement of the worktable and the wire.
Filtration System: A system of filters that cleans the dielectric fluid by removing eroded material, ensuring consistent cutting performance.
Cooling System: This keeps the machine's components, especially the wire, at optimal operating temperatures to prevent overheating and maintain cutting precision.
Automatic Wire Threading (AWT) System: Some advanced machines have an AWT system, which automatically threads the wire through the start hole in the workpiece. This feature is a time-saver and reduces manual labor.
What to Consider When Choosing Wire EDM Cutter
Material Compatibility: Ensure that the Wire EDM cutter is compatible with the materials you need to machine. Different machines perform better with specific metals, such as hardened steel, titanium, or aluminum.
Precision and Tolerance: Evaluate the machine's ability to maintain high precision and tight tolerances. Wire EDM is known for its accuracy, so consider the cutter's resolution and repeatability.
Wire Type and Diameter
Consider the type and diameter of the wire the machine uses. Different wire types (e.g., brass, coated) and diameters affect cutting speed, accuracy, and the ability to machine complex shapes.
Cutting Speed
Check the machine's cutting speed and efficiency. Faster machines can increase productivity, but make sure speed doesn't compromise the quality of the cut.
Machine Rigidity and Stability
A stable and rigid machine frame minimizes vibrations, improving cutting precision and surface finish. Consider the build quality and design of the machine.
Workpiece Size and Capacity
Ensure the machine can handle the size and weight of your workpieces. Check the table size, travel limits, and work envelope to ensure they match your requirements.
What Does a Wire EDM Cutter Require for Regular Maintenance?
AWT (Automatic Wire Threading): Performs the automatic wire threading. It is the single most important automated feature on the machine and allows for reliable unattended operation. It requires simple cleaning.
Power feed contacts (x2): These are sometimes called "energizer plates" and deliver the electrical cutting power to the wire. These contacts, both on the upper and lower machine heads, will erode over time, resulting in a significant decrease of machining speed. They require simple indexing/repositioning.
Rollers: All rollers and rubber wheels throughout the wire transport system must be cleaned periodically. Accumulation of debris on the rollers from the EDM wire will lead to wire slippage and/or wire tension problems. The clutch, or tension roller, will periodically need to be calibrated for proper wire tensioning.
Filtration System: (Performed periodically when needed) Requires replacement of the main filters. There may also be a secondary filter element that requires replacement for the AWT system.
De-ionization resin: (Performed periodically when needed) The DI resin is used to condition and control the conductivity level of the water. The resin will need to be changed and replaced.
Water reservoir: The water in the main reservoir will need to be monitored and maintained at a certain level due to loss from evaporation.
General cleaning: Periodic cleaning of the entire work tank and worktable is recommended. The debris generated by the Wire EDM cutter is very abrasive and will accumulate throughout the work tank over time. This debris, if not cleaned regularly, will be difficult to clean if allowed to build up, and will shorten the life of some machine components. Generally, the cleaner the machine is kept, the less likely it is that problems will arise.
Tank seals: Weekly and/or monthly cleaning of main door seals or sliding seal plates is recommended. Keeping these surfaces clean will prevent the buildup of debris and subsequent seal failure.
Electrical/generator cabinet: Clean and check the cabinet cooling fans for proper operation periodically.
Wire: The brass wire is only used once during operation, so the wire spool will need to be replaced once fully consumed. As part of best practices, operators may replace the spool to avoid the machine stopping and losing unattended machining time if the wire spool runs out. The spent wire will also need to be removed and recycled from the collection bin that is typically located in the back of the machine.
FAQ
Hot Tags: wire edm cutter, China wire edm cutter manufacturers, factory, servo wire cut edm machine, single axis edm machine, cut edm machine with linear motor, high precision servo wire cut edm machine, other edm, wire edm cutter
