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In daily life, it is often seen that electrical appliances produce sparks at the moment of switch closure or disconnection. The high temperature generated by the sparks melts the contacts, creating uneven spots. This phenomenon is known as electrical corrosion.
Electrical corrosion can cause poor contact in switches and ultimately damage them, which is its harmful aspect. However, with in-depth research into the phenomenon of electrical corrosion, not only can corrosion be reduced and prevented through scientific methods, but electrical corrosion has also been successfully used to process metals in various ways, leading to the invention of electrical discharge machining (EDM).
A thin metal wire slides over a metal material, accompanied by sparks flying, and in no time, the metal workpiece is cut. This is wire cutting—a method of machining that uses the principle of electrical erosion.
EDM wire cut machines do not cut the workpiece directly with a metal wire. Instead, they use a moving metal wire as an electrode. When there is a sufficient gap between the conductive metal wire and the metal workpiece for the pulse voltage to break through, spark discharges occur, creating high temperatures sufficient to melt and vaporize the material being processed, thus achieving the cutting of the material. Therefore, wire cutting is also known as electrical discharge cutting.
Due to the difficulty in controlling the cutting path, traditional wire cutting methods are difficult or impossible to use for machining complex-shaped workpieces. However, with the introduction of CNC (Computer Numerical Control), the machine only needs to follow a pre-written control program to position the cutting, easily achieving automated machining of various complex-shaped workpieces.
EDM wire cut machines have fast processing speeds and high machining accuracy, making them very suitable for processing small batch parts, single pieces, and complex-shaped products.
In some contact machining processes, such as CNC lathes and CNC milling machines mentioned earlier, the workpiece being machined is prone to deflection due to the cutting force.
However, EDM wire cut machines cut through sparks rather than drill bits or end mills, requiring no direct contact with the workpiece. The machining process basically does not experience shift, providing high machining accuracy, which is more suitable for machining thin workpieces with complex designs and high precision.
The machining method based on electrical erosion makes the cutting precision of wire cutting higher, but it also limits the materials that can be processed: electrical discharge machining can only process conductive materials and is not suitable for processing plastics, ceramics, wood, and other non-conductive materials.
Due to electrode wear caused by repeated discharges, EDM wire cut machines have relatively slower cutting speeds when processing corners and curves, ultimately leading to slower overall production speeds and increased costs.
EDM wire cut machine, with its unique machining principles and high precision capabilities, plays an important role in modern manufacturing. Although there are certain challenges in material selection and production speed, by optimizing operations and maintaining them properly, their advantages can be fully utilized, achieving efficient and precise metal machining. For workpieces requiring high precision and complex shapes, EDM wire cut machine is undoubtedly an ideal choice.
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