What is wire EDM?
Release date:
2022-04-06
The operating principle of wire EDM is to use a continuously moving molybdenum wire—also known as the electrode wire—as the electrode, generating pulsed spark discharges to erode metal and cut the workpiece into the desired shape. Its machining quality falls between that of conventional wire EDM and high‑speed wire EDM; more precisely, it represents an intermediate level: while it can achieve multiple cuts comparable to high‑speed wire EDM, its overall machining and cutting speeds are not slower—on the contrary, they often exceed those of high‑speed wire EDM. Only by intermittently reducing the cutting speed during the process can the intended cutting results be attained; in such cases, the calculated efficiency reflects an average performance, whereas the actual machining quality typically resembles that of slow‑feed wire EDM. The wire feed rate is automatically controlled by the system and can be adjusted as needed.
The operating principle of wire EDM is to use a continuously moving molybdenum wire—also known as the electrode wire—as the electrode, generating pulsed spark discharges to erode metal and cut the workpiece into the desired shape. Its machining quality falls between that of conventional wire EDM and slow-wire EDM; more precisely, it represents an intermediate approach: while it can achieve multiple cuts comparable to fast-wire EDM, its machining and cutting speeds are not slower—on the contrary, they often exceed those of fast-wire EDM. Only by intermittently reducing the cutting speed during the process can the desired results be attained; in such cases, the calculated efficiency reflects an average performance, whereas the actual machining quality typically resembles that of slow-wire EDM. The wire‑feed speed is automatically controlled by the system and can be adjusted as needed.
Wire EDM with medium-speed wire cutting features multi‑pass cutting capability (based on the same fundamental principles as slow‑feed wire EDM). The control system automatically adjusts machining process parameters—such as high‑frequency pulse width, pulse interval, number of power tubes, and wire feed speed—according to the programmed instructions. Moreover, during operation, users can selectively fine‑tune these parameters and manually modify the machining settings for specific workpieces.
The medium‑speed wire EDM maintains a simple, fast‑cutting structure, low costs, excellent process performance, and minimal consumable wear. By repeatedly incorporating internationally advanced mold‑processing equipment and slow‑wire cutting technology, the machine has been upgraded in hardware, enhancing both its precision and stability. The result is a more user‑friendly, convenient, and versatile machine. Consequently, medium‑speed wire EDM has significantly addressed the inherent shortcomings of poor machining quality in conventional fast‑wire EDM, while also substantially reducing mold‑manufacturing costs.
What is mid‑speed wire EDM? Mid‑speed wire electrical discharge machining (MS‑WEDM) falls under the category of reciprocating high‑speed wire EDM machines. It enables a variety of cutting operations on high‑speed reciprocating wire EDM machines and is commonly referred to as “mid‑speed wire EDM.”
Here, we clarify that the so‑called “medium‑speed wire EDM” does not simply refer to a wire‑feeding speed intermediate between high‑speed and low‑speed operation. Rather, it denotes a composite wire‑cutting machine tool: during rough machining, it employs the Chinese high‑speed wire feed (8–12 m/s), while in finish machining it switches to a lower speed (1–3 m/s). This approach ensures relatively stable cutting performance with minimal vibration, and repeated passes help minimize errors arising from workpiece deformation and molybdenum‑wire wear, thereby effectively improving part quality. As a result, the overall machining quality falls somewhere between that achieved by high‑speed and low‑speed wire EDM machines.
Therefore, it can be said that what users refer to as “middle‑line routing” is, in fact, a reciprocating‑line‑routing process implemented on a low‑speed routing machine, enabling streak‑free cutting and multi‑pass cutting. Practice has shown that, in multi‑pass machining, achieving high‑speed, stable cutting is the primary objective; by employing peak current with a long pulse width, high‑current cutting can be performed to attain elevated cutting speeds. The ultimate goal of the cutting operation is to refine the surface finish and ensure dimensional accuracy.
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