Wire cut machine EDM

Wire EDM machine uses a metallic wire (electrode) to cut a programmed

contour in a workpiece. Extrusion dies and blanking punches are very
often machined by wire cutting. In the machining area, each discharge
creates a crater in the workpiece (material removal) and an impact on the
tool (wear of the tool/electrode). The wire can be inclined, thus making it
possible to make parts with taper or with different profiles at the top and
bottom. The wire is usually made of brass or stratified copper, and is
between 0.02 and 0.33 mm diameter.
Why Use wire cut machine?

In practical terms, electrical discharge machining overcomes a major

issue found in contact machining: hardness. In traditional processes,
metal workpieces are made from special grades of hardenable tool steels
machined in an anneal of soft state to facilitate cutting.

One the desired shape has been machined, the parts are then hardened by
one or more heat treatments. This adds time, cost and can alter the
finished parts’ dimensions, especially if the heat treatment process is not
properly controlled.
Different Uses:-

Wire cutting machines can also be used to cut other materials such as
tubing, fiber optic cables, and heavy-duty twisted wire or ribbon cabling.
A tube cutting machine is used to cut lengths of copper pipe used in all
kinds of construction applications, including heating, ventilation, and
cooling. Tube cutters can use carbon dioxide based lasers, high-speed
water jets, or plasma oxyfuel flames for cutting copper tubing.

Wire cutting machines also include devices that use wire to cut other
materials. For example, customized foam pieces are often cut using a hot
wire cutting machine. A block of foam is mounted in the machine and a
specific shape is carved out of the block using a series of hot wires. A
foam wire cutting machine uses a taut metal wire which is heated to about
200 degrees Celsius. The heat vaporizes the polystyrene foam without
even coming into contact with the material, making a clean, precise cut.

Advantages and disadvantages

Advantages of Wire cut machine :-

 Complex shapes that would otherwise be difficult to produce with

conventional cutting tools.

 Extremely hard material to very close tolerances.

 Very small work pieces where conventional cutting tools may

damage the part from excess cutting tool pressure.

 There is no direct contact between tool and work piece. Therefore,

delicate sections and weak materials can be machined without
perceivable distortion.

 A good surface finish can be obtained; a very good surface may be

obtained by redundant finishing paths.

 Very fine holes can be attained.

 Tapered holes may be produced.

 Pipe or container internal contours and internal corners down to R .

001".
Disadvantages of Wire cut machine :-
 Difficulty finding expert machinists.

 The slow rate of material removal.

 Potential fire hazard associated with use of combustible oil based

dielectrics.

 Reproducing sharp corners on the workpiece is difficult due to

electrode wear.

 Specific power consumption is very high.

 "Overcut" is formed.

 Excessive tool wear occurs during machining.