Servo Wire Cut EDM Machine
Servo wire cut EDM machine is an accurate and effective method of producing custom parts and components from metal. The wire cut EDM machine machining services process utilizes an electrical current discharge between two electrodes, which are the tool and the workpiece. Servo wire cut EDM machine is widely used within a multitude of industries for creating components by cutting intricate shapes in numerous conductive and oftentimes delicate materials.
Benefits of Servo Wire Cut EDM Machine
Complex Shapes: The thin single-strand wire, coupled with CNC control, can produce extremely intricate 2D profiles and 3D shapes with tight internal radii and details. Wire as small as 0.02 mm can erode very fine details.
Accuracy and Repeatability: Machine accuracies reach 0.00004” (0.001mm) or better, with repeatability around 0.00008” (0.002mm). This is due to precise servo control of the wire and advanced power supplies that regulate the electrical discharges.
No Cutting Forces: Eliminating physical cutting forces allows servo wire cut EDM machine to machine delicate or fragile parts without distortion, cracks, or feature damage. Parts can be cut directly in the hardened state without geometric changes.
Low Heat Affected Zone: The heat from the closely controlled servo wire cut EDM machines is highly concentrated on a very small zone. This prevents damage to adjacent surfaces or distortion from excess heat.
Machining Hardened Metals: The servo wire cut EDM machines effectively cuts hard metals over 60 HRC that cannot be machined by other methods. Carbides, tools steels, and exotics with high hardness are ideal applications.
Burr-Free Cuts: The continuously moving wire produces an accurate, burr-free finish. No additional deburring or cleanup is required. The servo wire cut EDM machines yields excellent edge quality.
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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).
Aluminum: All aluminum alloys can be cut by servo wire cut EDM machine, providing smooth surface finishes while avoiding the rapid tool wear caused by machining. It is best suited for less complex aluminum part shapes.
Titanium: Titanium and its alloys like Ti-6Al-4V are readily machined by servo wire cut EDM machine, which prevents the stresses that lead to work hardening when conventionally machining titanium.
Steel
Servo wire cut EDM machine can cut all types of steel, from soft low carbon steels to the hardest alloy tool steels above 60 HRC. This enables intricate cuts in hardened tool steel not otherwise possible.
Brass
Free-machining brass alloys are easily cut by servo wire cut EDM machine with good accuracy and surface finish. The non-contact process avoids work hardening of the malleable brass.
Carbides
All forms of carbide tungsten, silicon, boron are commonly cut by servo wire cut EDM machine due to their extreme hardness making conventional machining impractical.
The Difference Between Servo Wire Cut EDM Machine and Traditional Cutting Machine
First of all, the traditional cutting machine cuts the workpiece through mechanical force, while the wire cut EDM machine cuts the workpiece through discharge to generate a high-temperature and high-voltage arc. This is also one of the biggest differences between the two.
Traditional cutting machines require the use of cutting tools for cutting, while wire cut EDM machines use electrode wires for cutting. The electrode wire is a thin wire that generates a high-temperature and high-voltage arc through discharge to cut the workpiece into the desired shape. Therefore, the cutting speed of the wire cut EDM machines is slower than traditional cutting machines, but the cutting accuracy is higher.
In addition, there is no mechanical force during the cutting process of the wire cut EDM machines, so no mechanical deformation will occur. The traditional cutting machine will produce mechanical deformation during the cutting process, which affects the cutting accuracy. Therefore, an wire cut EDM machines is more suitable for occasions that require higher cutting accuracy.
Wire cut EDM machines does not produce chips during the cutting process, because there is only discharge between the electrode wire and the workpiece during the cutting process, and no mechanical force is exerted on the workpiece. The cutting process of traditional cutting machines will produce a large amount of chips, which need to be cleaned. Therefore, an wire cut EDM machines is more suitable in situations where the waste generated during the cutting process is required.
How Does the CNC System Control the Servo Wire Cut EDM Machine?
The CNC system controls a servo wire cut EDM machine by precisely managing the movement of the wire and the workpiece along multiple axes. It does this by sending commands to the servo motors, which adjust the position and tension of the wire, as well as the relative position of the workpiece. The CNC system ensures that the wire follows the programmed path with high accuracy, allowing for the precise cutting of complex shapes and intricate geometries. It also monitors and adjusts parameters such as cutting speed, wire tension, and electrical discharge conditions to optimize the machining process.
What are the Typical Wire Materials Used in a Servo Wire Cut EDM Machine?
Copper wire
The first wire used for servo wire cut EDM machine was copper. It’s availability and high conductivity (100% IACS) made it a logical choice for an EDM electrode at the time, but as generators became more powerful, copper’s limited cutting speed and low tensile strength (34,000-60,000psi) quickly revealed it’s limitations.
Brass wire
The element zinc is added to copper to produce brass EDM wire, which is the most common EDM wire in use today. Brass wires for EDM are typically an alloy between 63/37 (American and European) to 65/35 (Asian), Cu/Zn ratio.
Coated wire
Coated EDM wires are wires that have had a very thin layer (2-3μm) of pure zinc applied to a brass or copper core. Electro-galvanization is the most precise method of application, depositing pure zinc, atom by atom onto the body of the wire, insuring uniform thickness and surface uniformity. It is a quicker and less precise method of coating and these wires will usually be less expensive.
Diffusion-annealed wire
Diffusion-annealed wires are available in tensile strengths from 62,000-128,000psi and appear yellowbrown to brown in color. These wires are suited for fast cutting of tall workpieces, volume production and in poor flushing conditions. They can be used against a wide range of materials including tool steels, aluminum and graphite.
Molydebnum wire
This is a very high strength wire with tensile strength in excess of 275,000psi. Because of its high tensile strength, moly wire aids in maintaining excellent wall straightness and reducing the number of wire-breaks common with many small and fine brass wires.
Steel-core wire
This type of wire has a core of carbon steel for high strength and fracture resistance and is clad with a thick layer of zinc-rich, diffusion-annealed brass to provide good cutting qualities. Steel core wire is an option when attempting extremely tall parts, parts requiring good straightness, and where poor flushing conditions exist.
Tungsten wire
Tungsten wire is often one of the last choices when trying to solve a difficult application. This allows it to cut very fine, very straight-walled details with sharp definition. Like moly wire, tungsten wire is also used on applications that must be free from copper or zinc in the cut surfaces.
Factors Affecting Tolerances in Servo Wire Cut EDM Machine
Machine Stability
A stable machine ensures better precision in cutting actions.
Wire Quality and Diameter
Its purity, diameter, and electrical traits influence the machining process. Optimal results require a balance between wire quality and diameter.
Workpiece Material
While some materials are more accessible to machines, the material choice must align with the application’s needs.
Flush Conditions
The flow of the dielectric medium, affects the quality of the machining process, aids in material removal, consistent electrical discharges, and effective heat dissipation.
Machine Calibration and Maintenance
The machine’s capabilities are pivotal. Superior machines with adept operators are essential for achieving the best tolerances.
Thermal Stability
To maintain the known precision, controlled electric arcs are crucial. Thermal instabilities can jeopardize accuracy, emphasizing the importance of consistent conditions.
Application of Servo Wire Cut EDM Machine
Automotive
Servo wire cut EDM machine technology is vital in the automobile industry, enabling the precision manufacturing of critical components like cylinder heads, valves, and fuel injectors, which require exact tolerances and complex shapes. It handles various materials, including alloys and tool steels, and is also essential for producing molds and dies for automotive part casting, stamping, and forming.
Aerospace
Aerospace manufacturing needs complex geometries and tight tolerances. Servo wire cut EDM machine helps craft intricate shapes in parts for landing gear, aircraft engines, and other crucial components. Furthermore, it is integral in creating molds for plastic injection parts used in aircraft interiors.
Medical Devices
Servo wire cut EDM machine is indispensable in medical manufacturing, offering the precision needed for producing complex instruments like forceps and intricate orthopedic implants. Its ability to meet strict specifications ensures the efficacy and compatibility of medical devices within the human body.
Electronics
With the servo wire cut EDM machine technique, microelectrodes—used in microelectronics for circuitry and sensors—can be produced with efficiency. These microelectrodes frequently need very tight tolerances to perform properly in electronic equipment. It is a great option because it can produce these components with micron-level accuracy. It is also useful in creating connector pins and lead frames for integrated circuit (IC) packaging due to its high level of precision.
Die Tooling
With servo wire cut EDM machine technology, injection mold inserts can be produced quickly. Often, these mold inserts need precise forms to guarantee the exact reproduction of the intended plastic parts, and this precision technique helps achieve this. Manufacturers also use it to create stamping dies to guarantee the correct formation of the sheet metal components. It is also useful for extrusion dies, blanking dies, shaping tools, and cutting punches.
Components of Servo Wire Cut EDM Machine
Wire: In wire EDM machines, the thin metallic wire, typically brass or copper, serves as the primary tool electrode.
Power Supply: This component supplies the electrical voltage between the wire and the workpiece in the wire cut EDM machine, producing the sparks essential for cutting.
Dielectric Fluid: Predominantly deionized water serves a dual purpose in a wire cut EDM machine. It acts as an insulator between the wire and workpiece and simultaneously flushes away the debris.
Servo Motors
These motors in the wire cut EDM machine dictate the wire's movement across the X, Y, and Z axes, adhering to the set path.
CNC System
Guides the full motion of the wire and optimizes all cutting parameters like voltage, speed, flow rate. The CNC program determines the shapes, angles, radii and finish.
Workpiece Fixturing
Secure and precise fixturing allows proper alignment and prevents any workpiece movement during cutting. Most critical for precision parts.
Wire Guides
The wire cut EDM machine's upper and lower precision guides, typically made of diamond or brass, play a pivotal role in maintaining wire positioning and tolerances. They are integral in averting wire deflection or potential breakage.
How to Maintain Servo Wire Cut EDM Machine
Regular cleaning
To clean a servo wire cut EDM machine, start by turning off the power and unplugging it from the electrical source. Use a soft brush or compressed air to remove any loose debris from the machine’s surface, paying close attention to hard-to-reach areas .eg. the gaps of guide wheel,the wire guide Next, use a mild detergent or cleaning solution to wipe down the machine, ensuring that all surfaces of wire cut EDM machine worktable,clamps,and wire cylinder are thoroughly cleaned. Avoid using abrasive cleaners or solvents that may damage the machine’s finish or components. Once the cleaning is complete, dry the machine with a clean cloth to prevent moisture from causing rust or corrosion. in general,the cleaning work of servo wire cut EDM machine is done once a month.
Lubrication
After cleaning, it is crucial to lubricate the servo wire cut EDM machine to ensure smooth operation. Begin by identifying the lubrication points, which are typically indicated in the machine’s manual. Apply a small amount of lubricant to each point, using the central automatical lubrication system on the wire cut EDM machine.The lubricating oil will be carried to the essential parts of machine by setting the regular activation parameters.Be careful not to over-lubricate, as excess lubricant can attract dust and debris, leading to clogging or damage. It is recommended to use a high-quality lubricant specifically designed for servo wire cut EDM machines to ensure optimal performance and longevity.The lubrication is pergormed once a week.
FAQ
As one of the leading servo wire cut EDM machine manufacturers in China, we warmly welcome you to buy discount servo wire cut EDM machine from our factory. All customized machines are with high quality and low price.
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