Complete EDM Handbook - 6

83
6 Reducing Wire EDM

Costs
Wire EDM costs can be greatly reduced if the material has been properly
prepared and the EDM process is understood. Unfortunately, the opposite is also
true. Wrong preparation can be costly.
Create One Slug

To reduce costs, the general aim should be to create one slug. Wire EDM is an
automatic process; if more slugs are made, it requires more down time and operator
services. Also, when surfaces close to an edge are cut, inadequate flushing occurs
which reduces cutting speed.
When entering a workpiece on a slight angle, feathered-edge machining occurs.
This feather-edge machining may cause slight surface irregularities. Skim cutting
can be used to remove such irregularities; however, unnecessary skim cuts increase
cost. Cutting one slug is much more cost effective. See Figures 6:1 - 6:4.
Feathered-Edge Machining
This makes six slugs.
Figure 6:1
Wrong Procedure—Creates six slugs and slows the process with feather-edge machining
Complete EDM Handbook
84 Compliments of www.ReliableEDM.com
Leave at least 3/16″ (9.84 mm).
Small hole in center

creates one slug.
Figure 6:2
Right Procedure—Creates one slug which produces more efficient machining
Figure 6:3
Wrong Procedure—Creates Five Slugs—Five starting cuts must be made,
and five times the machine must be stopped to remove each slug.
Figure 6:4
Right Procedure—Creates One Slug—Leaving extra material
on the outside allows for one slug to be cut.
Reducing Wire EDM Costs 85
Keeping Flush Nozzles on the Workpiece

The most efficient method for wire EDMing is placing both top and bottom
flush nozzles on the workpiece as shown in Figure 6:5. This placement allows for
maximum flushing pressure to remove the eroded chips.
Figure 6:5
Most efficient cutting occurs when both flush nozzles rest on the part.
If possible, nozzles that are not on the workpiece should be avoided because it is
less efficient because of less water pressure in the cut. See Figure 6:6.
Figure 6:6
Cutting with nozzles not on the workpiece is possible, but it is less efficient.
For many applications, however, there is no alternative but to have nozzles off
the workpiece. At our company, Reliable EDM, we cut many jobs with nozzles off
the workpiece, including tall parts. See Figure 6:7.
Figure 6:7
An 11-1/2 Inch (292 mm) test specimen cut out of a large gear with nozzles off the workpiece.
Machining After Wire EDM

To avoid cutting with nozzles off the workpiece, it is sometimes more economical
to do machining after, rather than before the EDM process. This is particularly true
with shallow recesses as in Figure 6:8.
A Wire Cut Openings Recess
A View AA
Figure 6:8
Machine the Workpiece After Wire EDMing
Since the recess is shallow, it is more efficient to do the EDMing when the part is solid.
Often parts are stacked to reduce costs. When parts have intricate dimensions,
stacking may be difficult if parts have been previously machined as shown in
Figure 6:9.
1.922
.250
±.002
Figure 6:9
Holes should be put in after EDMing.
Making one piece presents no problem; however, parts like these are stacked. If holes are
premachined, it is difficult to line up the holes when cutting large stacks.
If parts can be stacked, it is preferred that holes be put in after the part has been
EDMed. Putting holes in first can cause alignment difficulties when the parts are
set up in a fixture as in Figure 6:10.
5/8″
Figure 6:10
Put tapped hole in after EDMing.
Parts like these are often stacked in a “V” block. Higher machining costs occur
because tapped holes cause alignment difficulties.
Cutting Multiple Plates and Sheet Metal Parts

Stacked sheet metal can be held with fixtures without the need for welding.
However, when multiple parts from one stack and starter holes are required, the
stack can be bolted with flat head screws or welded on its sides. The stack should
be flat, and the EDM job shop should be consulted for the ideal stack thickness.
Accuracy, efficiency, and machine capabilities determine the height for stacked
parts.
Wire EDM will cut through light rust; however, heavy rust and scale must be
removed. Many times plates are warped. The plates should be clamped tightly
together before welding. At least 1/2″″ (13 mm) should be left on the sides for
welding and clamping the part. See Figure 6:11 for proper stacking.
Flat Head Bolts
1/2″ (13 mm)

from edge
Weld
Figure 6:11
Stacks Welded or Bolted
At least 1/2″ (13 mm) should be left for clamping and a frame to support part while cutting.
Caution: If parts are welded or bolted, both sides of plates must be clean and
free from heavy scale, tape, paper, or any other non-conductive materials.
If sheets or plates are badly warped, each stack should be divided in half and the
belly should hit the center. The ends are then clamped together and welded. The
aim should be to produce a flat surface. The weld should be removed from the top
and bottom of the stack so flush ports do not hit the weld.
When putting stacks together, all sheets must be clean—marker paint, (not magic
marker), scale, tape, or paper between the sheets must be removed. Wire EDM cuts
by spark erosion; it cannot cut through non-conductive materials.
Production Lots
Wire EDM is an excellent machining method for production work. Fixtures
are often used to hold the multiple parts. It is important that production lots are
machined the same in the area where they will be located. Parts also need to be
machined square. See Figure 6:12.
Outside diameter should

be the same and square
to assure accuracy
.005 TIR
Figure 6:12
Production EDMing—When machining parts, consideration should be made for stacking.
Stipulating Wire Sizes

Some machines can cut with .0008″″ (.020 mm) wire. One wire EDM job was
done on a .015″″ (.38 mm) diameter air turbine rotor. It had 13 slots cut with .00039″
(.01 mm) wire. This was done on a specialized wire EDM machine.
The difficulty with cutting with thin wires is that it machines much slower
because less energy can be applied to the wire. Also, thin wires break much more
easily than standard wire sizes. Some applications require thin wires; however,
whenever possible stay with the standard wire size of .010″″ (.25 mm) or .012″ (.30
mm) wires. Stipulating thin wire can add significant costs to the wire EDM process
because of slower cutting feeds and difficulties associated with such wires.
Pre-Machining Non-Complicated Shapes

It is not always necessary to EDM the entire part. Sometimes pre-machining can
reduce costs as shown in Figure 6:13.
Pre-machined surface
Weld
Figure 6:13
Pre-Machine Parts to Reduce Costs.
Wire EDM is an extremely efficient method to machine parts. However, costs

can be further reduced by understanding this unique process of cutting metal. In
the next chapter we will be discussing the advantages of wire EDM in tool and die
making. Understanding this process can result in substantial savings in producing
stamping dies.

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83

6 Reducing Wire EDM

Create One Slug

This makes six slugs.

Leave at least 3/16″ (9.84 mm).

Small hole in center

Keeping Flush Nozzles on the Workpiece

Machining After Wire EDM

A Wire Cut Openings Recess

Cutting Multiple Plates and Sheet Metal Parts

Flat Head Bolts

1/2″ (13 mm)

Outside diameter should

Stipulating Wire Sizes

Pre-Machining Non-Complicated Shapes

Wire EDM is an extremely efficient method to machine parts. However, costs

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