Wire EDM
Wire EDM (Electrical Discharge Machining) is a precision metalworking process used to produce complex shapes and extremely tight tolerances, especially in hard and hardened materials. The process is based on controlled electrical discharges between a thin wire electrode and the workpiece, removing material without any mechanical contact.
In our production process, we use the Mitsubishi MV1200 (Figure 1), a modern EDM machine designed for high precision, stability, and repeatability. This model is particularly well suited for manufacturing tools, molds, and precision engineering parts where conventional milling or turning cannot achieve the required quality or geometry.
Figure 1 – Mitsubishi MV1200 Wire EDM
Mitsubishi MV1200 in practice
The Mitsubishi MV1200 features a robust and thermally stable construction, precise axis control, and an advanced pulse generator. This combination enables an optimal balance between cutting speed and surface quality, even when machining thick or technologically demanding materials. Independent control of the upper and lower wire guides allows for tapered cuts and high geometric accuracy across the entire height of the workpiece. Automatic control of discharge parameters, wire tension, and flushing contributes to a stable process, reduced risk of wire breakage, and high repeatability of results, which is especially important in serial production.
Principle of wire EDM operation
During machining, a brass or coated wire continuously moves between the upper and lower guides, while the workpiece is submerged in deionized water. Electrical pulses between the wire and the workpiece cause controlled micro-erosion of the material along a precisely defined CNC tool path. Since there are no cutting forces, very hard materials can be machined without deformation or internal stresses.
Advantages of wire EDM
Wire EDM provides extremely high accuracy and excellent surface quality. Tolerances in the range of a few microns are standard, and the resulting surface finish often does not require additional finishing operations. A key advantage is the ability to produce sharp internal corners and complex contours that are not achievable with conventional cutting tools.
Applications of wire EDM
Wire EDM is most commonly used in the production of plastic injection molds, stamping tools, precision mechanical parts, gears, and hardened components with complex geometries. All electrically conductive materials can be machined, including tool and stainless steels, titanium, copper alloys, and tungsten carbide.
Conclusion
Wire EDM is an indispensable process in modern precision manufacturing. By using the Mitsubishi MV1200 machine, we ensure a high level of accuracy, consistent machining quality, and flexibility in producing technically demanding parts, with full process control and repeatable results.
HDDSMachining
