WIRE EDM
The Wire EDM is increasingly used to make prototypes and production parts in a wide range of industries, including automotive, aerospace, and electronics. Our Wire EDM equipment and advanced technology are the critical aspects for advanced superior tolerance of parts and repeatable and extensive tooling with ultra-fine finishes. Whether you need prototypes, short production runs, or mass quantity, Sundi Tools will delivery on time with quality assurance.Unleash Precision with Sundi’s EDM Services: Where Advanced Machinery Meets Expertise. Elevate Your Projects with Our Exceptional Quality, Swift Turnaround, and Competitive Rates, Ensuring Your Market Dominance.
What Is WIRE EDM
Wire EDM (Electrical Discharge Machining) is a precise manufacturing process where a desired shape is obtained by using electrical discharges (sparks). In this process, a thin, electrically charged wire acts as an electrode that cuts the material, creating intricate and detailed shapes with a high degree of accuracy. Ideal for hard metals or materials that are difficult to machine using traditional methods, Wire EDM is renowned for its precision, allowing for the production of complex components with fine tolerances. This technique is widely used in aerospace, automotive, and tool & die industries for creating intricate parts and detailed tools.
Why Choose Us for Wire EDM
Choosing Sundi for wire EDM processing means partnering with a provider who is committed to excellence, precision, and customer satisfaction, making us a reliable choice for your complex machining needs.
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Mass Capacity and Short leadtime
At Sundi, we employ 20+ set state-of-the-art wire EDM machines that enable us to reach the production requirements shortly.
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Expertise and Experience
With a team of highly skilled professionals, Sundi boasts extensive experience in wire EDM.
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Versatility in Materials and Applications
We can work with a wide range of materials, including hard-to-machine metals and alloys.
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Customization and Flexibility
Sundi offers customized solutions to meet your specific requirements.
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Quality Assurance and Precision
We adhere to strict quality control protocols and use precision measuring tools to ensure the accuracy and quality.
- Quality Assurance
- OEM/ODM Service
- Cost Saving
- Fast Delivery
How Can We Operate and Control The Quality?
By focusing on these areas, quality during Wire EDM processes is meticulously controlled and maintained, ensuring high-quality outputs consistent with client specifications and industry standards
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Precision Equipment Use
Utilizing high-precision Wire EDM machines that are regularly calibrated for accurate performance.
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Consistent Wire Quality Maintenance
Ensuring the use of high-grade, consistent-quality wires for uniform cutting.
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Real-time Monitoring
Employing advanced software and monitoring systems to track the machining process in real-time, allowing for immediate adjustments as needed.
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Regular Machine Maintenance
Conduct routine maintenance on Wire EDM machines to prevent malfunctions and ensure consistent operation.
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Skilled Operator Training
Providing extensive training for operators to understand the nuances of Wire EDM, ensuring they can effectively manage and adjust the process.
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Quality Control Checks
Implementing rigorous quality control measures, including post-machining inspections using precision measurement tools to verify dimensions and surface integrity.
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Optimized Cutting Parameters
Setting and regularly reviewing machine parameters like voltage, current, feed rate, and water quality to maintain optimal cutting conditions.
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Documentation and Process Tracking
Keeping detailed records of all machining processes, settings, and maintenance activities for accountability and continuous improvement.
The Wire Diameter Used for Wire EDM
The choice of wire diameter depends on the specific requirements of the machining task, including the level of precision needed, the thickness of the material being cut, and the desired speed and efficiency of the cutting process. Smaller diameters are typically used for high-precision tasks, while larger diameters are chosen for faster cutting of thicker materials,Here are the common wire diameters used in slow wire EDM (Electrical Discharge Machining).
| Wire Diameter(mm) | Common Uses |
|---|---|
| 0.10 | Precision machining,fine details |
| 0.15 | General purpose,balanced precision and eddiciency |
| 0.20 | Standard cutting,widely used in various applications |
| 0.25 | Thicker materials,requiring higher cutting efficiency |
| 0.30 | Heavy-duty cutting,lager parts,lower precision needs |
What kind of material is suitable for Wire EDM
Since Wire E.D.M requires electrical interaction with the machining material, Only the conductive material can be processed in the EDM process, The following material is a good choice for Wire E.D.M service.
Carbide machined by wire E.D.M for wide applications
- Hard Tool Steels for wire E.D.M machining
- Stainless Steel-corrosion parts for wire E.D.M
- Titanium for wire E.D.M service
- Conductive Copper for wire E.D.M Service
- Aluminum corrosion resistance in E.D.M machining
- Alloys with high performance used for E.D.M machining
Common Issues When Wire EDM Processing
In slow wire EDM (Electrical Discharge Machining), a precise cutting technique, several common issues can arise. These challenges require careful planning, appropriate machine settings, and sometimes innovative solutions to ensure high precision and quality, Here are some of these challenges, described in English:
- Wire Breakage: One of the most frequent issues in slow wire EDM is the wire breaking during the cutting process. This can be due to factors such as incorrect wire tension, poor wire quality, or inappropriate machine parameters.
- Surface Finish Quality: Achieving a high-quality surface finish can be challenging. Factors like the type of material being machined, wire type, and machine settings can affect the surface finish.
- Taper and Corner Accuracy: Maintaining accuracy in tapered surfaces and sharp corners can be difficult. This precision is often crucial for the functionality of the machined part.
- Material Thickness Issues: Cutting very thick materials can lead to problems like reduced accuracy and increased wire wear, affecting both the quality of the cut and the efficiency of the process.
- Maintaining Consistent Accuracy: Achieving consistently accurate cuts throughout the entire process can be challenging, especially when dealing with complex or intricate designs.
- Heat Affected Zone (HAZ): The EDM process generates heat, which can affect the material around the cut, potentially leading to changes in the material properties.
- Debris and Filtration: The process generates a significant amount of debris, which must be effectively filtered and removed to maintain cutting efficiency and precision.
- Cost and Speed: While slow wire EDM is known for its precision, it can be slower and more costly compared to other machining processes, especially for large volumes or less complex cuts.
The Advantages of Wire EDM
The Wire EDM is one of the popular machining methods for offering more benefits compared with other manufacturing process.
EDM is a highly cost-effective machining way, and it can be used to cut various conductive materials with high accuracy, great finish, and less distortion.
1: Cost-effective. When creating dies and molds for manufacturing operations, EDM can be used to cut and shape materials directly. Since wire EDM does not rely on pressure, it can cut both hard and delicate materials accurately at a high rate of speed, It makes the production ability more efficient. Meanwhile, The system of Wire EDM is highly automated, less labor is needed compared with the grinding process. In addition, the process of Wire EDM is a saving manufacturing process that greatly reduces material and labor costs.
2: Minimal distortion. The Wire EDM is a valuable manufacturing machining process to cut various hard, thin, and fragile materials, It won’t damage the surface or edge of the cutting workpiece. The regular machining way is easy to create distortion around the cutting area. Not only this distortion will damage the integrity of the machining material, but it may also influence the cutting parts’ performance. In general,the EDM process is a quick and accurate way to machine conductive materials without damage.
3: High fabrication speed.Compared with other machining ways, Wire EDM has less preparation that requires an additional finishing process. The program can be quickly set up in the Wire EDM system, and parts can be produced following the orders, then the machining components will have smooth surfaces and tight tolerance.
4: Extreme accuracy. Wire E.D.M is an extremely precise cutting method, which is more precise than laser and traditional cutting. Since the components are cut without external pressure. The part can be cut four times without additional finishing, first rough cutting, then precision cutting. The Wire EDM use very fine brass wire to cut different shapes within tight tolerances.
5: Suitable for complex components. The Wire EDM is very suitable for producing very small or complex components, this offers a great advantage for aerospace and electronic applications that requires extremely strict details with high accuracy requirements.
