The Ultimate Guide to Choosing the Right Wire Cutting Machine for Your Business

Estimated reading time: 5 minutes

The world of wire-cutting machines is very competitive. Suppose a company has a high enough budget. As a result, they can even afford to hire engineers and experienced CNC specialists knowledgeable in wire-cutting machines. But we all know that not every business has money to spare to buy new equipment.

What steps should you take before making a significant investment in your business? Consequently, as with any large purchase, you should start with the basics, type of features, and your needs as a manufacturer.

About Innovation Filter System

Interestingly, we started our company- Innovation Filter System, by making filtration systems for wire-cutting machines back in 1999. However, we have never bought, used, or operated a wire EDM. However, our association with this industry has been since the birth of the Innovation Filter System. Hence, we would like to share the knowledge. So, let’s begin with some basics.

Basics #1: Benefits of using a wire-cutting machine

Wire-cutting machines are essential to the manufacturing industry because of their precision and speed. Therefore, they allow you to make prototypes, micro parts, and fully functional products.

Workpiece thickness

Wire EDMs can cut parts up to 24″ thick and workpieces as small as .002″.

Cutting hard materials

Wire EDMs are meant for difficult-to-machine materials like Tungsten carbide, hardened tool steel, titanium etc.

A wire EDM can hold tolerances of +/- .0001″ with excellent repeatability.

Superior surface finish

Wire EDMs can achieve a surface finish as fine as 4 RA (32 micro inches).

Not heat distortion

Wire EDM cutting takes place in a bath of de-ionized water, which cools the workpiece and tool. Hence, there is no heat distortion or damage to the workpiece material while cutting.

Burr-free cutting

The wire-cutting machine cuts using electric current rather than direct mechanical contact. Hence,  there is no need to lubricate it or remove chips from the cutting surface. Therefore, we lose much less material when using the wire EDM versus conventional cutting methods.

Basics #2: How does an EDM wire-cutting machine work?

EDM- Electrical discharge machining process works on the basic principle of spark generation and metal removed by spark erosion. 

Wire EDM creates an electrical charge between a wire electrode and a workpiece. Therefore, when the spark jumps across the gap, it removes metal from the workpiece and the wire.

Basics # 3: Components in a wire-cutting machine

Now, let’s get a bit technical- A typical system consists of-

1. CNC unit
2. Power supply with anti-electrolysis circuitry
3. A mechanism for automatic wire threading
4. Tank to contain the dielectric fluid
5. Chiller to keep the dielectric at a steady temperature
6. Filtration system for dielectric fluid

Wire-EDM used an electrically charged wire fed from a reel and moved through upper and lower guides. Consequently, this process superheats the wire as it passes across a power contact at the top and bottom of the machine.

Basics #4: How does a wire-cutting machine cut?

The wire-cutting machine sends a current between the wire and the workpiece, causing millions of sparks to fly. Therefore, this sparking generates heat, about 15,000 degrees Fahrenheit—enough to melt away microscopic bits of the workpiece, creating fine cuts and intricate shapes.

Moreover, the volume of material removed during the short period of intense heat is relatively small. However, the frequency and the number of sparks generated briefly make it an effective process to cut narrow slots or intricate shapes in rigid materials.

However, please note that the wire also loses material because of the sparking action. Hence, the wire gets consumed. Therefore, many of these machines come with an automatic wire threading mechanism.

Basics #5: Why submerged wire-cutting?

Submerged cutting

You may have noticed that the workpiece is submerged under water during the wire-cutting process. Have you ever wondered what this water is? This water is called de-ionized water. Hence, a dielectric fluid helps carry the spark generated between the wire and the workpiece. Consequently, submerging the wire and the workpiece in de-ionized water helps flush away the debris caused by the wire cut machine.

Splash flushing

One way to rinse away debris in a wire cut machine is to submerge the wire and part in clean water. Gravity carries away the sediment; however, one must constantly direct the top and bottom nozzle at the wire. The other method is splash flushing. This method is fast because it doesn’t require gravity assistance. However, operators need to adjust the nozzles often as the motion of the wire displaces them. When machining is submerged, cutting occurs in a more easily controlled environment.

Basics #6: How many axes does a wire cut machine have?

As you may know, a CNC unit moves the machine in an X-Y plane. It can position the upper guide independently in the U-V axis. Hence, simultaneous repositioning of all four axes (X, Y, U, V) allows the wire cut machine to cut tapers or shapes that transition from top to bottom. A programmable Z-axis enables workpieces with different thicknesses to be machined automatically.

Conclusion

In conclusion, a wire-cutting machine is an excellent addition to any manufacturing company’s toolkit of machinery. But if you’ve never bought one before, it can be intimidating. Hence, this blog! So, whether you’re already a pro or still have a few questions, we hope this blog answers some of them. If not, please comment below, and we will get them answered.