What is EDM?

A Brief History

The acronym EDM is derived from Electrical Discharge Machining.

The EDM process we know today started with the observations of Joseph Preistly in 1770.
He noticed that electrical discharges had removed material from the electrodes in his
experiments. This is also known as electro-discharge erosion.
In the 1940's two Soviet researchers, the Lazarenkos', developed a machining process that
formed the foundation for modern EDM.
Electric Discharge Machining

The basic EDM process is really quite simple. An electrical spark is created between an

electrode and a workpiece.

The spark is visible
evidence of the flow of electricity. This electric spark produces intense heat with
temperatures reaching 8000 to 12000 degrees Celsius, melting almost anything. The spark
is very carefully controlled and localized so that it only affects the surface of the material.
The EDM process usually does not affect the heat treat below the surface. With wire EDM
the spark always takes place in the dielectric of deionized water. The conductivity of the
water is carefully controlled making an excellent environment for the EDM process. The
water acts as a coolant and flushes away the eroded metal particles.
Wire Cutting

EDM wire cutting uses a metallic wire to cut a programmed contour in a workpiece.
Extrusion dies and blanking punches are very often machined by wire cutting. Cutting is
always through the entire workpiece. To start machining it is first necessary to drill a hole in
the workpiece or start from the edge. On the machining area, each discharge creates a
crater in the workpiece and an impact on the tool. The wire can be inclined, thus making it
possible to make parts with taper or with different profiles at the top and bottom. There is
never any mechanical contact between the electrode and workpiece (see above). The wire is
usually made of brass or stratified copper, and is between 0.1 and 0.3 mm diameter.
Depending on the accuracy and surface finish needed, a part will either be one cut or it will
be roughed and skimmed. On a one cut the wire ideally passes through a solid part and

drops a slug or scrap piece when it is done. This will give adequate accuracy for some jobs,
but most of the time, skimming is necessary. A skim cut is where the wire is passed back
over the roughed surface again with a lower power setting and low pressure flush. There
can be from one to nine skim passes depending on the accuracy and surface finish required.
Usually there are just two skim passes. A skim pass can remove as much as 0.002" of
material or a as little as 0.0001". During roughing ( i.e. the first cut) the water is forced into
the cut at high pressure in order to provide plenty of cooling and eliminate eroded particles
as fast as possible. During skimming (accuracy / finish cuts) the water is gently flowed over
the burn so as not to deflect the wire.

Xact Wire EDM Corporation - N8 W22399 Johnson Dr Waukesha, WI 53186