Wire EDM

Wire EDM (or WEDM – Electrical Discharge Machining) is a process that cuts or shapes a workpiece using electrical sparks. This method is preferred when high precision is required for hard metals and complex shapes, providing a unique solution for cutting and shaping electrically conductive materials.

In wire EDM technology, a thin wire acts as an electrode, generating electrical sparks between the wire and the workpiece. These sparks melt and vaporize material from the workpiece at a microscopic level, resulting in highly precise and clean cuts. The process is usually performed in water or a specialized dielectric fluid, keeping the cutting area clean and maintaining high accuracy. Additionally, the capability to perform large-scale wire EDM cuts offers a significant advantage for projects requiring precise machining of large components.

Although wire EDM can be slower compared to other machining methods, its high precision, superior surface quality, and ability to handle complex geometries make it indispensable in various industrial applications.

Advantages of Wire EDM

Wire EDM cutting technology offers numerous important advantages:

• High Precision: Wire EDM is ideal for operations requiring extreme accuracy, capable of producing fine and intricate cuts.
• Hard Materials: It is highly effective for hard-to-machine materials such as titanium, tungsten carbide, and heat-treated steels.
• No Thermal Deformation: The low thermal impact during cutting eliminates the risk of thermal deformation in the workpiece.
• Superior Surface Quality: Smooth and high-quality surfaces can be achieved even at high cutting speeds.
• Large-Scale Cutting: Wire EDM can precisely machine large and complex components, thanks to its extended cutting capabilities.
• Tight Tolerances: Wire EDM is perfect for producing parts that require very tight tolerances. Multiple cuts on the same surface can achieve dimensions with 0.001 mm accuracy.
• 800 mm Wire EDM Capacity: The wide axis movement allows for precise machining of large workpieces.

Wire EDM Machines at Cermak Kalıp

With our expertise in die manufacturing, our company fulfills our customers’ subcontract wire EDM cutting needs with the highest quality and precision. Our machine park includes three Fanuc CNC wire EDM machines.

These machines are equipped with linear scale options and standard temperature change sensors to meet high-precision requirements. Additionally, one of our machines features a rotary indexer, which, together with an additional axis called the A-axis, allows complex tolerance parts to be clamped and precisely cut in a single operation. Another machine, with an 800 mm X-axis and 600 mm Y-axis travel, provides ideal solutions for large-scale wire EDM applications.

The axis travel specifications of our machines are as follows:

Fanuc Robocut 1iD CNC Wire EDM

• X axis: 600 mm 
• Y axis: 400 mm
• Z axis: 310 mm
• A axis: 360°

Fanuc Robocut C800iB CNC Wire EDM

• X axis: 800 mm
• Y axis: 600 mm
• Z axis: 310 mm

All our CNC wire EDM machines are of Japanese origin, and Japanese wires are used to achieve maximum performance. To maintain the highest levels of precision and surface quality, operations can be performed with up to six cuts.

Wire EDM Applications

Wire EDM cutting has a wide range of applications and is used in various industries, including the following:

• Tool and Die Manufacturing: Production of high-precision components, such as plastic injection molds, sheet metal dies, and extrusion dies.
• Prototype Production: Rapid and accurate prototype production in new product development processes.
• Precision Component Manufacturing: It is one of the most suitable machining methods for parts requiring extremely tight dimensional tolerances, such as microelectronic components, medical device parts, and aerospace industry components.
• Large-Scale Wire EDM: With an 800 mm X-axis travel, it is ideal for large-scale projects that require high precision.
• Customized Cuts: Unique and customized cutting services for your special designs and projects.
• Medical and Electronic Applications: Effective solutions for components requiring micro-level precision.
• Rotary/Indexed Wire EDM Cutting: Simultaneous 5-axis cuts with continuous rotary motion or indexed cuts can be performed.

Wire EDM cutting also enables the execution of complex and detailed projects in various industries, such as aerospace, energy, and precision equipment manufacturing. In these processes, high precision and low error rates are key factors that enhance production efficiency.

Wire EDM Hourly Rate

The hourly rate for subcontracted wire EDM may vary depending on the characteristics of the workpiece and the requirements of the project. The following factors play a significant role in pricing:

• Material type
• Material quantity and dimensions
• Precision and tolerance requirements
• Design and shape complexity

Our company provides project-specific pricing to offer the most suitable solution. To request wire EDM cutting services or obtain detailed information, you can contact us and send your drawings and requirements to our email address.

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