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Wire EDM Services


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Wire EDM Primary

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Wire EDM is a method to cut conductive materials with a thin electrode that follows a programmed path. The electrode is a thin wire. Typical diameters range from .004" - .012" (.10mm - .30mm) although smaller and larger diameters are available. The hardness of the work piece material has no detrimental effect on the cutting speed. There is no physical contact between the wire and the part being machined. Rather, the wire is charged to a voltage very rapidly. This wire is surrounded by deionized water. When the voltage reaches the correct level, a spark jumps the gap and melts a small portion of the work piece. The deionized water cools and flushes away the small particles from the gap.

The CNC machine can independently move four machines axes to generate taper cuts. A stamping die can be machined with 1/4 degree taper or a mold with one degree taper in some areas and two degrees in another with precision. Extrusion dies can be cut with the taper constantly changing. For example, a detailed shape on the top of the work piece can transition to a simple circle on the bottom.

Wire EDM can be accurate to +/-.0001". Virtually no burrs are generated. Since no cutting forces are present, wire EDM is ideal for delicate parts. No tooling is required so delivery times are short. Pieces up to 16" thick can be machined. Tools and parts are machined after heat treatment so dimensional accuracy is held and not affected by heat treat distortion.



Capabilities · Specifications · Equipment Used · Inspection Equipment · Additional Information

Capabilities

Wire EDM Capabilities

High Taper
Small Diameter Wires
Auto-threading
Submerged cutting for thermal stability and efficient interrupted cutting
Anti-electrolysis power supply

Other Services

Prototyping
Reverse Engineering
Laser Marking
Small Hole Wire EDM

Production Quantity

High Volume Production
Prototype

Quality Control Certifications

ISO 9001:2008

Quality Control Process

CMM
SPC
Video

Software Used

CADKEY
Esprit
PEPS Camtek
SolidWorks

Specifications

Materials

All Tool Steels
Stainless Steel
Aluminum
Inconel
Tungsten
Carbide
Nickel
Brass
Copper and Copper Tungsten
Kovar
Invar
Platinum
Molybdenum
Titanium
Nitinol
Tantalum
Hastalloy
Poly Crystalline Diamond (PCD)
Refractory Materials
CPM – 10V

Wire Material

Brass
Stratified Copper

Wire Diameter

0.003 to 0.012 in
0.08 to 0.30 mm

Material Removal in Skim Pass

0.0001 to 0.002 in

Positional Accuracy

0.000020 in

Tolerances

+/- .0001 in
+/- .0025 mm

Work Piece Thickness

Up to 16 in

Taper Angles

to +30 º

Acceptable File Formats

DXF
DWG
IGS
PRT
X - T
STP
SLDPRT
Native Solidworks

Equipment Used

3 - Charmilles Robofil CF400 Wire EDM Machine

12.6" x 17.7" travel
10.5" thick

5 - Charmilles Robofil 510 Wire EDM Machine

15.7" x 27.5" travel
16" thick
30º taper

4 - Charmilles Robofil 300 Wire EDM Machine

9.8" x 15.6" travel
16" thick
30º taper

3 - Charmilles Robofil 290 Wire EDM Machine

9.8" x 15.6" travel
8" thick
30º taper

1 - Charmilles Robofil 230 Wire EDM Machine

8.6" x 13.8" travel
8" thick
30º taper

1 - Sodick AQ 300L LN1 Wire EDM Machine

7.87" x 11.81" travel
7.87" thick
25º and 20º taper

4 - Sodick AQ 537L Premium Wire EDM Machine

14.57" x 22.44" travel
13.78" thick
25º taper

3 - Sodick AQ 327L Wire EDM Machine

14.5" x 10.6" travel
9" thick
20º taper

2 - Charmilles Robofil 4020 Wire EDM Machine

12.6" x 17.7" travel
14" thick
30º taper

2 - Charmilles Robofil 510 Wire EDM Machine

15.7" x 27.5" travel
16" thick
30º taper

2 - Charmilles Robofil 310 Wire EDM Machine

9.8" x 15.6" travel
16" thick
30º taper

1 - Charmilles Robofil 300 Wire EDM Machine

9.8" x 15.6" travel
16" thick
30º taper

1 - Charmilles Robofil 290 Wire EDM Machine

9.8" x 15.6" travel
8" thick
30º taper

Inspection Equipment

OGP Avant ZIP 300 Video Inspection System (multi-sensor)

12" x 12" x 8” travel
38 X to over 300 X magnification
Automated Reverse Engineering
Equipped with 1/10th Micron Glass Scales (4 Millionths Resolution)

OGP Smartscope ZIP 250 Video Inspection System

6" x 10" travel

OGP Flash 500 Video Inspection System (multi -sensor)

18" x 18" travel

OGP Avant 600 Video Inspection System

18" x 24" travel

1 - Brown & Sharpe Global Image 575 CMM

Available with PH10M indexable head and PCDMIS CAD++

2 - Brown & Sharpe Reflex 454 Coordinate Measuring Machines

18" x 20" x 16" with reverse engineering capabilities

2 - 14" Profile Projectors

Available with 10x 20x and 50x lenses and linear digital scales

2 - Sets of Mitutoyo Digimatic Holtest gages

Available with .0001" accuracy

1 - Mitutoyo Height Master

Available with .00005" graduations and digital readout

Other Equipment

Optodyne MCV-500 Laser Doppler Displacement Meter
1 - Mahr Digimar CX 1 Height Measuring Station
Minitab statistical software package
Advanced CAD/CAM equipment with file transfer and translation capabilities
GT Schmidt Microlase laser marking and pin stamping systems

Additional Information

Wire EDM Advantages

Low work holding forces
Low cutting forces
Very accurate process tolerances
Complex profile capability
No tool wear (the wire is continually replenished)
Hardened materials are easily machined
Small corners, narrow slots
No burrs
Ideal for delicate parts
No tooling required

Specialties Served

Machined Parts
Stamping Dies
Trim Dies
Extrusion Dies
Mold Components and Electrodes
Gauges and Fixtures
Prototypes
Exotic Materials
Form Tools
Blanking Punches
Medical Components

Industries Served

Automotive
Consumer Products
Paper Processing
Defense
Electronics
Energy
Food Processing
Marine
Medical
Packaging
Aerospace
Nanotechnology

 MORE IMAGES 

· Wire EDM

· Ball Valve

· Charmilles 300 series Auxillary Flush

· Charmilles 4020

· Class A Progressive Die

· Machining

· Precision Skim Cutting

· EDM Inspection Equipment

· Avant ZIP 300 Video Inspection System

· CAD/CAM software

· Coordinate Measuring Machine

· Medical Components

· Multi-operation Production Parts

· Typical Wire EDM Parts

· Marine Industry Mold

· Communication Industry Thin Walled Production Part

· Aluminum Component

· Small Parts Example #1

· Small Parts Example #2

· Small Parts Example #3

· Laser Marking #1

· Laser Marking #2

· Endoscopy Rings

· Fibre-Optic Clips

· Mold Core Electrical Connector

· Small Gears

· Titanium Part for Heart Instrument

 DOWNLOADS 

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