Wire EDM

TUOWEI takes great pride in delivering precision and accuracy with every Wire EDM project. The process is highly technical but allows us to create intricate, high-quality components with tight tolerances. 

Below is a detailed overview of the Wire EDM process we use to ensure each part meets our high standards.

Design and Engineering

The process begins with the design phase, where our team works closely with you to understand your project needs. Whether you’re looking to create a simple part or a complex, intricate design, our experienced engineers will ensure the CAD (Computer-Aided Design) files are prepared accurately for the Wire EDM process.

• Client Consultation: We start by discussing your specifications, materials, and dimensions to ensure clarity before proceeding.
• CAD Modeling: Once we have a clear understanding of your design, we convert it into a CAD model, which serves as the blueprint for the Wire EDM machine.
• Feasibility Check: Our engineers assess the design to ensure it’s optimized for Wire EDM, including ensuring that all features can be cut with precision.

Preparing the Wire EDM Machine

Once the design is ready, our team sets up the Wire EDM machine, carefully selecting the right wire and making the necessary adjustments to ensure optimal cutting performance.

• Wire Selection: The wire used for the process is typically made from brass, copper, or other materials depending on the job requirements.
• Machine Calibration: We calibrate the Wire EDM machine for precision by adjusting settings such as cutting speed, voltage, and wire tension. 
• Tooling and Fixturing: After setting up the machine, we create the necessary fixturing to securely hold the workpiece in place, ensuring stability during the cutting process.

Cutting the Workpiece

With the setup complete, the Wire EDM machine starts the cutting process, using the wire to precisely cut through the material.

• Electrical Discharge: A series of rapid electrical discharges pass between the wire and the workpiece, vaporizing the material and forming the desired shape. 
• Continuous Monitoring: During the cutting process, our technicians closely monitor the operation. The machine can cut continuously or in layers, depending on the complexity of the design.
• Precise Movements: The Wire EDM machine moves the wire along the programmed path, cutting with a high degree of precision. 

Post-Production

Once the cutting process is complete, the part moves into post-production, where it undergoes finishing and inspection to ensure it meets our exacting standards.

• Deburring and Surface Finishing: After cutting, the part may require additional finishing steps such as deburring to remove sharp edges or applying a surface finish for smoother results.
• Dimensional Inspection: Each part undergoes rigorous dimensional inspections using tools like CMM (Coordinate Measuring Machines) to verify that it adheres to the specifications and tolerances outlined in the original design. 
• Final Quality Check: Before delivery, our quality control team conducts a final inspection to ensure the part meets all the customer’s requirements. 

Why is Wire EDM the Right Choice for Your Project?

Wire EDM is the optimal solution for projects requiring high precision and intricate designs that traditional machining methods cannot achieve. Unlike other machining processes, Wire EDM works with hard materials such as titanium, tool steels, and carbide, maintaining tight tolerances down to ±0.001mm or finer. This level of precision ensures that even the most demanding parts are produced with exact specifications, resulting in minimal post-processing and enhanced performance.

Wire EDM excels in producing parts with minimal heat-affected zones (HAZ), reducing the risk of material distortion. This makes it perfect for delicate components where traditional methods might introduce warping or stress. It is also highly efficient for low-to-medium volume production, as the setup time and flexibility of the process allow manufacturers to adapt quickly to design changes.