2/1/2006 | 9 MINUTE READ

BUILD | EDM | MOLD MATERIALS

Maintaining a Wire EDM Machine

To achieve the ultimate capability and level of productivity from your wire EDM on a consistent, re
reliable basis, regular maintenance is a required task.

BRIAN R. PFLUGER, EDM PRODUCT MANAGER, MAKINO

Over the past three decades, wire EDM (electrical discharge machining) has advanced an
transformed into an everyday, commonly relied upon process. The capabilities and perfo
today’s wire EDM machines continue to develop and improve in the three main machini
characteristics: speed, accuracy and surface finish.

Gains in machining speed have reduced overall process cycle times while also delivering
repeatable dimensional accuracy. These wire EDM machines can automatically thread w
0.001 inches in diameter through holes barely larger than a human hair. And they can p
like surface finishes with micro-machined part details so minute that they require a mic
with the human eye.

In order to accomplish this capability and level of productivity on a consistent, repeatab

basis, these modern technology marvels must be maintained on a regular schedule, acco
manufacturers’ recommendations.

Maintenance Intensive
A wire EDM machine may be one of the most maintenance intensive pieces of equipmen
shop environment. This should not be a concern, as this does not downplay any of the m
productive capability nor indicate any excessive downtime. It does, however, elevate the
disciplined preventive maintenance schedule.

For example, a highly-tuned automobile racing engine will not produce at its rated horse
performance levels without regular care and scheduled maintenance. A wire EDM mach
much in the same manner, and will not perform to the speeds, finishes and accuracies th
for if not properly maintained.

The main difference between wire EDM and other traditional machining processes in re
maintenance is that it must be done as a proactive and preventive measure. Adherence t
maintenance at recommended intervals is crucial to the process performance!

Due to the electro-mechanical nature of wire EDM machines, there are several items in n
that routinely wear and require cleaning and/or replacement. If certain machine compo
properly cared for, machining speeds and accuracies will rapidly decay.

The most important reason to properly schedule and perform this routine wire EDM ma
ensure consistent and repeatable machining results for the aforementioned machine tra
accuracy and surface finish. This level of maintenance also prevents machine failure an
machine downtime.

There are several wire EDM machine tool manufacturers, and there are some significan
the machine design of each. But the importance and type of basic items that need to be m
wire EDMs are very similar. When planning and scheduling wire EDM machine mainten
actions can be grouped into short interval and long interval items.

Short Interval Items

Short interval items vary in occurrence from weekly to monthly.

1. Automatic Wire Threading System: The automatic wire threading (AWT) system per
threading of the wire via a water jet column. It is the single most important automa
wire EDM machine. Utilization of an AWT system will extend the unattended operat
machine. AWT units typically require cleaning and alignment checks of mechanical
sensors to ensure reliable operation.
2. Power Contacts: These two contacts deliver the electrical cutting power to the wire.
both on the upper and lower machine heads—will erode over time, resulting in a si
decrease of machining speed. They require a simple indexing and cleaning, and eve
replacement.
3. Belts and Rollers: These items make up the wire transport system. They require eith
indexing, or replacement to prevent wire slippage or wire tension problems that ca
inaccuracies.
4. Brake/Clutch Roller: This roller is the most critical item in the wire transport system
create and control the proper tensioning of the wire. If wire tensions are not held to
parameters, workpiece inaccuracies, exces-
sive wire breaks and excessive wire lines on the workpiece may result. This unit is t
maintained with the aid of an OEM (original equipment manufacturer) supplied pro
calibration cycle.
5. Wire Guides (2): These guides—either diamond or sapphire—are located in both the
machine heads. They are used to align and locate the wire within the machine. The
most important item within the machine because they deliver and transfer the mac
 accuracy into the workpiece. They require cleaning to prevent misfeeding, clogging
inaccuracies and failure.
6. Wire Alignment: This procedure is typically required after wire guide cleaning with
OEM supplied jig or fixture, and is performed to calibrate and align the wire within
verticality. If the wire is not properly aligned for verticality, machined results will c
positional part locations will be inaccurate.
7. Wire Collection Box: The wire is only used once within the machine, and will accum
bin that will need to be emptied periodically. The spent or used wire should be rout
emptied per manufacturer recommendations. The spent material can typically be r
an industrial materials scrap recycler.
8. Machine Seals: Many machine designs require cleaning of a door and tank seal to en
integrity and longevity. Seals will need to be replaced once they become degraded b
service life and can no longer sufficiently prevent or control water leakage.
9. General Cleaning: With the intricate wire EDM process, debris is typically scattered
throughout the work tank. Over time, this debris can accumulate and build up into
is difficult to clean. Scheduling a monthly machine cleaning using a standard cleane
large buildups of debris. Less overall time will be required the more frequent the cl
Generally, the cleaner a machine is kept, the less likelihood there is for unsuspected
arise. This also may extend the life of some long interval consumable items.

Long Interval Items

Long interval items vary from bi-monthly to yearly.

1. Machine Filters: Replacement of the main water filters will be required and should
needed (most machines will typically generate an alarm when the filters are deplete
intervals are purely dictated by the type of work, workpiece material and thickness
being performed. Many machines also contain a safety filter for the AWT system tha
replacing periodically (six to 12 months). The filtration system on a wire EDM is fun
necessary because it controls the amount and size of particles/debris that can exist
through the flushing system during machining. If this debris is excessive and of a la
size, machining will be very unstable and inefficient.
2. De-ionization Resin: This is a special resin that is used to control the conductivity of
the machine. If the conductivity or resistivity of the water is not controlled and sust
level that the machine requires, machining will become very unstable, and final res
inaccurate. The de-ionizing (DI) resin is replaced when needed (most machines will
generate an alarm when the resin is depleted). There also is a conductivity/resistivit
requires cleaning to ensure proper level readings.
3. Water Level: Over time, the water level in the machine reservoir will become low fr
and will need to be replenished. The quality of the incoming water (tap water is typ
affect the life of the DI-resin.
 4. Belts, Rollers and Pulleys: Certain machine designs require periodic replacement of
rubber rollers and pulleys. Replacement may be required due to physical wear of th
from wear of replaceable bearings. It is very important that these items be maintain
and/or replaced by specific procedures and intervals suggested by your machine too
Failure to keep these items within operational specifications will result is part inacc
machine downtime.
5. Wire Choppers: Some machines contain a wire chopping unit that cuts the used or s
small pieces. Maintenance on this unit will include the sharpening or replacement o
and dies. The results of allowing these cutting edges to become excessively dull will
workpiece inaccuracies, excessive wire lines on the workpiece and machine downti
6. Cabinet Filters: Some machine designs require the changing or cleaning of an air fil
filters are commonly found on intake fans of the electrical/generator cabinets and w
These filters should be inspected, cleaned and replaced at regular intervals specifie
these filters become excessively clogged, air flow will be restricted, which will lead
and failure of the equipment.
7. Machine Seals: Due to specific seal designs, some seals and/or gaskets may require a
replacement to ensure proper machine operation. The seals/gaskets that typically re
attention are the work tank door gasket and the lower arm tank seal plate. Proper m
care of the lower arm sliding seal plate is especially important because as this seal w
increases, machining accuracies also may be degraded.
8. Machine Floats: Most manufacturers recommend a yearly inspection and cleaning o
operational and safety float switches. If these floats become excessively dirty, their
fail, resulting in damaged machine electrical components and water spillage.
9. Water Reservoir: The quality level of the water within the machine can become deg
and heavy sediments also can build up in the water holding tanks. Contaminants fr
agents also can change the pH levels of the water, all of which can affect the perform
machine. Most wire EDM manufacturers recommend that the water be drained and
reservoir cleaned yearly. Insufficiently monitoring and maintaining the reservoir sy
in excessive machine corrosion, sedimentary buildup and machine component/pum
10. Machine Lubrication: Check with your machine’s OEM on recommended intervals a
for machine lubrication. The most common items that require attention are the ball
linear guide way systems. Be sure to use the proper lubricants that are specified by
Improper lubrication of the machine will lead to workpiece inaccuracies and the ev
replacement of costly machine mechanical components.

General Cleaning Importance

Good cleaning habits and care of a wire EDM machine is highly recommended. Regular a
cleaning of the machine also can extend the life of some consumable items.

Care should be taken when selecting a cleaner. It is recommended that a general, all-pur
cleaner/degreaser be used for general cleaning. A mild, watered-down solution of acid (t
cleaners are phosphoric acid based) is used for the cleaning of more heavily soiled mach

When using any cleaner, it is best to apply the cleaner to a rag and not directly spray cle
machine. This will result in using less cleaner as well as controlling the contamination o
reservoir.

Do not allow caustic or acidic cleaners to sit on some surfaces too long as they may etch,
damage surfaces. And avoid getting cleaners on attachment points where power cables c
machine heads, as cleaners can act like a corrosive agent and degrade the power cables.

After cleaning, be sure to wash and rinse cleaned surfaces with water. This will ensure t
are properly removed prior to operation.

Keep in mind, the underlying concept and operating strategy for wire EDM is to maximiz
machining time. With a properly maintained wire EDM machine, the goals of maximizin
time and greater overall process efficiency can be more easily achieved and realized.

Due to machine design differences, the type and time intervals of machine maintenance
highly recommended to check with and follow the maintenance specifications, intervals
supplied by your machine OEM. If maintenance requirements, procedures or intervals a
contact your OEM or refer to your machine’s maintenance manual for more information