Hansheng Automation (Dongguan) Co., Ltd. is one of the most experienced manufacturers and suppliers of high-quality wire edm parts in China. If you're going to wholesale bulk cost-effective high-quality wire edm parts made in China, welcome to get pricelist and quotation from our factory. Also, customized service and OEM&ODM service are available.
Hansheng Automation supplys various high-quality parts and capable of providing automated solutions. Wire EDM is one of our professional services, our wire EDM parts are high-quality and can meet different requirements from customers. Due to high-quality and strong supply capacity, more and more customers have chosen us as their strategic partner.
Feature
high precision
Wire EDM parts can achieve nanometer-level precision, the machining accuracy of parts can reach ±0.01mm or even higher. Wire EDM is suitable for the parts which have extremely high requirements for precision, such as molds, precision instrument components, etc.
Complex shape machining capability
Wire EDM can process complex two-dimensional contours which is difficult to achieve for traditional machining, such as narrow slit, profiled hole, fine structure, etc. Wire EDM parts are suitable for aerospace, medical devices and other fields, which have requirements for complex parts.
Extensive material adaptability
The materials of Wire EDM parts are extensive, wire EDM parts can be manufactured by various conductive materials, including materials of high hardness and high toughness, such as quenched steel, carbide alloy and titanium alloy etc.
Machining without cutting force
Electrode wires don't contact the workpiece directly and don't have macro cutting force during the machining process, so the workpiece is not easily deformed. Wire EDM is suitable for manufacturing parts which are thin-wall and deformable, such as thin plate, slender shaft-type components, etc.
High surface quality
The machined surface roughness of wire EDM parts is low and can reach Ra0.1μm-0.8μm. Wire EDM can reduce subsequent processing operation, improving production efficiency and surface quality of parts.
high utilization ratio of materials
Only necessary materials are removed during the cutting process, remaining materials can be continued to use. Wire EDM is particularly suitable for precious metal processing, which can reduce material costs.
high automatic extent
The processing trajectory of Wire EDM is controlled by numerical control program, which makes wire EDM realize automated production. This can improve production efficiency and consistency, reducing manual intervention.
Low tool cost
Wire EDM don't need to manufacture tool anode with complex shape and directly use thin metal wires (such as molybdenum wire, copper wire) as electrodes. This can reduce the cost of tool design and manufacturing.
Process
Preparation
Workpiece blank preparation
Selecting suitable materials according to the processing requirements, such as alloy tool steel (for example Cr12, Cr12MoV etc.). And performing the heat treatment process such as forging, annealing, quenching, etc., to reduce machining deformation.
Threading hole machining
If internal cavities or complex shapes are required to be cut, it is necessary to pre-process the threading hole in the workpiece, which ensure electrode wire can pass through smoothly.
Equipment inspection
Turning on the power supply of the machine tool and check the high-frequency power supply, water pump, wire drum and other components for normal operation or not.
Clamping And Adjustment
Workpiece clamping
Choosing suitable jig (such as cantilever type, two-end supported type, bridge supported type, etc.), fixing the workpiece firmly on the workbench and ensuring the cutting part is within the travel range of machine tool.
alignment and positioning
Adjusting the position of the workpiece by using dial indicator or lineation method, which enables workpiece reference surface to maintain parallelism with the surface of machine's worktable and feed direction (X-axis, Y-axis). This step can guarantee the processing precision.
Installation And Adjustment Of Electrode Wire
Upper thread piercing
The electrode wire (such as molybdenum wire, tungsten wire, brass wire, etc.) is installed on the wire drum of machine tool and pass through the threading hole of workpiece, ensuring that the perpendicularity of electrode wire meets requirements.
wire positioning
Ensuring the starting cutting position of electrode wire through visual inspection, spark method, or automatic centering function, making the relative position of electrode wire and workpiece reference surface accurate.
Parameter Setting And Programming
Selection of process parameters
Based on the workpiece material, thickness, accuracy requirements, etc., adjusting parameters such as pulse width, pulse interval, peak current, and wire feed speed.
Programming
using CNC programming software to draw the machining path based on the workpiece contour, generating machining program and input it into the machine tool control system.
Machining Process Monitoring
Start processing
Turning on the working fluid pump and adjusting the nozzle flow rate, ensuring the working fluid is fully sprayed onto the cutting area, and then cooling, cleaning, and insulation.
Real-time Monitoring
Observing the wire walking, discharge, and working fluid circulation, etc., promptly handling issues such as broken wires, short circuits, and insufficient working fluid flow.
Post-Processing
Part inspection
Check whether the dimensional accuracy, shape accuracy, and surface roughness of the parts meet the requirements after processing.
Cleaning and maintenance
Cleaning electro-erosion products in the working fluid tank, maintaining machine tool, and preparing for the next machining process.
Application
FAQ
Q: How about the machining efficiency of wire EDM parts?
A: Machining efficiency is influenced by various factors, such as workpiece material, shape complexity, machining allowance, etc. Generally speaking, the machining efficiency of wire EDM is relatively low, but it can produce parts with high precision and complex shapes. For simple parts, the machining time may be shorter, for complex parts, it may take longer.
Q: Do you provide samples?
A: We will provide samples according to the requirements of customers, so that customers can confirm the machining quality and craftsmanship. The sample cost and lead time need to be evaluated.
Q: What materials can be processed?
A: Wire EDM is mainly applicable to conducting materials, such as metals like steel, copper, aluminum, titanium, and their alloys. For some hard materials that is hard-to-machine, such as cemented carbides and ceramics, wire EDM can also demonstrate its advantages.
Q: How about the processing cost of wire EDM parts?
A: The processing cost of wire EDM mainly includes equipment depreciation, electrode materials, machining fluid, power consumption, etc. Due to processing efficiency is relatively low, the processing cost may be higher. However, by optimizing the processing technology, improving equipment utilization and reasonably controlling electrode wear, the processing cost can be reduced.
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