ONA WIRE EDM

The Fundamentals

ONA EDM USA

Addison, IL
USA

As we enter the 21st Century, the demands for higher precision in machining, ease of operation,
increased durability of parts, and long life of machines is greater than ever before. Manufacturer’s today
are faced with challenges of finding highly skilled workers, and designers need more latitude and
flexibility in their designs.

CNC Wire EDM can satisfy and accomplish all these needs. The precision machining of complex
geometry’s can be easily accomplished with minimal operations and operator intervention.
 ABSTRACT

��Wire EDM Fundamentals

�� Features on ONA wire EDM equipment

Todays wire electrical discharge machines have many features and improvements from machines
manufactured in the past. This paper is intended to give you a better understanding and basic overview of
the fundamentals, features and practical uses of Wire EDM.

-2-
Wire EDM

Wire EDM (Vertical EDM's kid brother), is not the new kid on the block. It was introduced in the late
1960s', and has revolutionized the tool and die, mold, and metalworking industries. It is probably the
most exciting and diversified machine tool developed for this industry in the last fifty years, and has many
advantages to offer.

Common materials such as tool steel, aluminum, copper, and graphite, to exotic space-age alloys
including hastelloy, waspalloy, inconel, titanium, carbide, polycrystalline diamond compacts and
conductive ceramics are routinely EDM’d. It doesn’t matter how hard the material is, as long as it’s
electrically conductive, it can be machined easily. During cutting, the wire doesn’t touch the workpiece,
so there is no cutting pressure or mechanical stresses imparted on the workpiece compared to milling
cutters and grinding wheels. Also, very little clamping pressure is required to hold small, delicate, or thin
fragile parts, thus preventing them from becoming distorted.

The accuracy, surface finish and time required to complete a job is extremely predictable, making the
process much easier to quote. EDM leaves no residual burrs on the workpiece, eliminating secondary
de-burring operations that save both time and money. Additionally, EDM leaves no tooling marks, as the
surface has a uniform, random pattern compared to marks that are left by grinding and milling operations.

Wire EDM also gives designers more latitude in designing dies, and management more control of
manufacturing. Parts that have complex geometry and close tolerances don't require you to rely on
different skill levels or the use of different machines. Substantial increases in productivity is achieved
since the machining is untended, allowing operators to do work in other areas. Most machines run
overnight in a "lights-out" environment. Long running jobs are cut overnight or over the weekend, while
shorter jobs are scheduled during the day.

Many times, multiple jobs are set up on the worktable and linked together with multiple programs. For
example, the die openings and dowel pin holes can be machined on a one-inch thick die block, and when
these openings are completed, the machine moves to another location, automatically threads the wire
and cut the punches required for the job in a much thicker piece of material. Most work pieces come off
the machine as a finished part, without the need for secondary operations. It's a one-step process!

Part repeatability is another very important feature of wire EDM. Prototype parts or short production runs
are cut individually or by laminating stacks of material together. The parts are identical, even if cut again
six months later.

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ONA "AF" SERIES
RE-250
Machine table travels of: 13.78” x 9.84” x 7.87”
Sizes
RE-400 table travels of: 23.62” x 15.75” x 15.75”
Machine Sizes
RE-900 table travels of: 35.43” x 15.75” x 15.75”
ONA ARION
ONA “KE” SERIES
manufactures these 4 different submerged wire EDM's of various sizes to fit the needs of the consumer.
KE-350 column travels of: 21.65” x 13.78” x 15.75”
ONA manufactures these 4 different submerged wire EDM's of various sizes to fit the needs of the consumer.
ONA "AF" KE-450
SERIES column travels of: 27.56” x 19.70” x 15.75”
RE-250 table
AF 25 table travelsof:of:15.7”
travels
KE-500 13.78” xtravels
x 11.8”
column 9.84”
x 9.8”x 7.87”
of: 27.56” x 19.70” x 15.75”
ONA "AF" SERIES
RE-400
AF 35 table table
travels of:travels
23.6” xof:
15.7”23.62” x 15.75”
x 15.7” x 15.75”
KE-1000 column travels of: 59.10” x 39.37” x 23.60”
RE-250
RE-900 table travels
tableof: 13.78”
travels of: x 9.84”
35.43” xx 7.87”
15.75” x 15.75”
The KE-1000 is the worlds largest submersible Wire EDM
ONA “AX” SERIES
RE-400 table travels of: 23.62” x 15.75” x 15.75”
ONA ARION “KE” SERIES
AX 6 column travels
RE-900 KE-350 table of: 31.5”of:
travels x 23.6” x 19.7”
35.43” x 15.75” x 15.75”
(It can accommodate work column
piecestravels of:
measuring 21.65” x 13.78”
up to 90.6” x 15.75”
x 63.0” x 23.6” and weighing up to 22,000 lbs.)
ONA ARIONAX 10“KE”
column
SERIES travels of: 59.10” x 39.37” x 23.60”
KE-450 column travels of: 27.56” x 19.70” x 15.75”
The AX-10 is theKE-350
worlds largest
columnsubmersible
travels Wire EDM
KE-500
The Arion RE-Series columnof:
has table movement,
21.65”
travels x 13.78”xx19.70”
whileof:the27.56”
15.75”x 15.75”
KE-series machines employ column movement on
The KE-450
AF-Series has table movement
KE-1000 column travels
in thetravels
column of:
X axis,of:
while27.56” x 19.70”
the AX-series
59.10” x 15.75”
x 39.37” xmachines
23.60” employ column movement
the axes.
on
TheallKE-1000 KE-500 column travels
axes. is the worlds largest submersible Wire EDM of: 27.56” x 19.70” x 15.75”

Column KE-1000 for thecolumn travels of: 59.10” x 39.37” An

x 23.60”
Column movement
movementallows
allows for the machining
machiningof heavier workpieces.
of heavier workpieces. advanced annealing
An advanced wire threader
annealing wire
The
(It
is KE-1000
standard is
can accommodatethe worlds
work
on all theon largest
pieces
AX-Series, submersible
measuring
along withalong Wire EDM
theupcapability
to 90.6” xto63.0” x 23.6”
use up and weighing ofupwire.
to 22,000 lbs.)
threader is standard all the KE-Series, with the capability totouse
a 100
up lb.
to aspool
100 lb. spool of wire.

(It can accommodate The AX upSeries is unique

x 63.0” with U/V and
travels of overup19toinches,
The Arion RE-Series work pieces
has table measuring
movement,
The while
tothe
KE-500
90.6”
KE-series x 23.6”
is unique machines
weighing
with U/Vemploy
travelscolumn
of over
22,000 lbs.)on
movement
18 inches,
the axes. providing the movement to cut tapers of +/- 28° in 15.75 inch
providing the movement to cut tapers of +/- 28° in 15.75 inch
The Arion RE-Series has table movement,
thickwhile
parts the
overKE-series
the entiremachines employ
table travels. The AFcolumn
Seriesmovement
has the on
thick parts over the entire table travels. The KE-450 has the
the axes. movement allows for the machining
Column same configuration
of heavierand X /Y travelsAn
workpieces. as the AX Series, with
same configuration and X /Y travels as advanced
the KE-500, annealing wire
with standard
standard
threader is standard on all the KE-Series, tapering
along with movement
the capability of the
upU/V
to aaxes. ( +/- 9° inof15.75in
tapering movement of thetoU/V
use axes. (100
+/-lb.
9°spool
in 15.75in wire.thick
Column movement allows for the machining of
thick parts) heavier workpieces. An advanced annealing wire
parts)
threader is standard on all the KE-Series, along
The with the capability to use up to a 100 of
lb. spool of
18wire.
The AXKE-500
Series isis unique
uniquewith
with
U/VU/V travels
travels of over 19over
inches, inches,
The KE-350 wire EDMto (see figure 1)+/-represents current
providing the movement to cut tapers of providing
+/- 28° in the movement
15.75 cut tapers
inch thick parts over theofentire 28°
tableintravels.
15.75 inch
technology. The system consists of a CNC The KE-500
control,overis unique
power supply with U/V travels
with anti-electrolysisof over 18 inches,
The AF Series has the same configuration thick
andparts
X /Y travelstheas entire
the AXtable travels.
Series, Thecircuitry,
with standard KE-450 dielectric
taperinghas the
system, automatic wire threading, handsameproviding the movement
held configuration
pendant, glass X to
/Y cut
andscales, tapers of KE-500,
programmable
travels as the +/-“Z”
28°axis,
in 15.75
with inch
astandard
lifetime
movement of the U/V axes. ( +/- 9° in 15.75in thick parts)
maintenance free filtration system, water thick parts
chiller
tapering overwire
unit,
movement the of
entire
the table
chopper,U/V100travels.( +/-The
lb. wire
axes. 9° KE-450
spool hasthick
incapacity,
15.75in the
anti-
same configuration and X /Y travels as the KE-500, with standard
vibration pads and levelers as standard equipment.
parts)
The AF 35 wire EDM (see figure 1) represents current technology. The system consists of a CNC control,
tapering movement of the U/V axes. ( +/- 9° in 15.75in thick
power supply with anti-electrolysis circuitry, dielectricfigure
system, automatic wire threading, hand held
The KE-350 wire 1EDM (see figure 1) represents current
parts)
pendant, glass
technology. scales,
The systemprogrammable
consists of a “Z”
CNC axis, anti-vibration
control, pads with
power supply and levelers as standard
anti-electrolysis equipment-
circuitry, dielectric
and a lifetime
system, maintenance
automatic wire threading, handThe
free filtration heldKE-350
system*, waterwire
pendant, glassEDM
chiller unit*,
scales,(see
wire figure 1) represents
chopper*
programmable current
“Z” axis, a lifetime
technology.
maintenanceThe freesystem
figureconsists
filtration 1system, of a CNCchiller
water control, power
unit, wiresupply with 100
chopper, anti-electrolysis circuitry,
lb. wire spool dielectric
capacity, anti-
-5-
system,
vibration automatic wire threading,
pads and levelers handequipment.
as standard held pendant, glass scales, programmable “Z” axis, a lifetime
maintenance free filtration system, water chiller unit, wire chopper, 100 lb. wire spool capacity, anti-
vibration pads and levelers as standard equipment. figure 1

figure 1

-5-

-5-
Major Components

A Wire EDM system is comprised of four major components.

(1) Computerized Numerical Control (CNC)

Think of this as “The Brains.”

(2) Power Supply

Provides energy to the spark.
Think of this as “The Muscle.”

(3) Mechanical Section

Machine tool, worktable, taper unit, and wire drive mechanism.
Think of this as “The Body.”

(4) Dielectric System

Water reservoir provides for filtration, and controls the condition and temperature of the water.
Think of this as “The Nourishment.”

We'll look at each of these components in more detail, but first lets look at how wire EDM works.

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Principle of Wire Electrical Discharge Machining

The Spark Theory on a wire EDM is basically the same as that of the vertical EDM process. With wire
EDM, conductive materials are eroded and vaporized with a series of high frequency electrical
discharges (sparks) that are produced between an accurately positioned moving wire (the electrode) and
the workpiece in the presence of a dielectric. These high frequency pulses of alternating or direct current
is discharged from the wire to the workpiece through an insulated dielectric fluid (water) creating a very
small discharge spark gap.

Many sparks can be observed at one time, because actual discharges can occur more than one hundred
thousand times per second, with discharge sparks lasting in the range of 1/1,000,000 of a second or less.
The volume of metal removed during this short period of spark discharge depends on the desired cutting
speed and the surface finish required.

By raising the amperage for a given discharge frequency, the cutting speeds will increase however, the
surface finish will become slightly rougher. Keep in mind that it is the repeated ON and OFF time of the
spark that removes material, not just the flow of electric current. The heat of each electrical spark,
estimated at around 15,000° to 21,000° Fahrenheit, erodes away a tiny bit of material that is vaporized
and separated from the parent material. The resulting particles (chips) are flushed away from the gap
with a stream of clean, de-ionized water from the top and bottom flushing nozzles.

The water also cools the workpiece and prevents heat build-up, preventing thermal expansion of the part.
The wire erodes a narrow slot through the workpiece creating the contoured shape that is programmed.
Some of the wire material is also eroded away making it no longer accurate. This is why fresh, new
accurate wire is continuously fed through the slot.

Simultaneous, controlled movement of the worktable in the X and Y-axes allows parts to be cut to one or
two tenths (0.0001”) accuracy routinely. The U and V axes are used to incline the upper portion of the
wire when taper cutting is required. The Z-axis controls the height position of the upper guide.

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Computer Numerical Control (CNC)

Today’s numerical control is produced with the needs of the operator in mind. Programs, machine
coordinates, cutting speeds, graphics, diagnostics and relevant information is displayed on a color TFT,
with easy to use menus. The machine can even be operated without knowledge of NC program codes.
Display screens can be viewed in many different languages i.e.: English, Spanish, German, Italian,
French, Swedish, Polish, and more with a simple push of a button.

The control unit displays a “Windows” style environment with drop down menu’s etc. that are designed to
give top priority to operability. Characters and commands are input using a trackball or the keyboard.
The system is very easy to use, allowing the operator to quickly become familiar with it, resulting in
his/her learning curve being drastically reduced.

The numerical control offers the capabilities of scaling, mirror imaging, rotation, axis exchange and assist
programs. This enables an operator to produce an entire family of parts from a single program without
the need to edit the program. Mirror imaging is great for left
and right-handed parts. Scaling is useful when working with
"shrink factors" for plastic molds or extrusion dies. Assist
programs automatically find the edge of parts, vertically align
the wire, and perform internal and external centering routines
that are very helpful to the operator when setting up jobs.

Besides executing NC data for positioning movement of the

axes, the control amends these movements when using
offsets, tapering, scaling, rotation, mirror images, or axis exchange. The machine also has multiple
coordinate systems. For example, multiple jobs can be set-up on the worktable, while storing the
separate locations of these jobs in specific coordinate registers. Jobs can be programmed in absolute or
incremental modes saving valuable programming time.
Other features include technology to aid in the prevention of wire breaks, corner control, adjusting for
tapering accuracy, maintenance and diagnostic screens, background editing and a graphic display of
programs even while the machine is running. Codes in the program can also adjust flushing pressure,
wire speed, and wire tension.

Programs are
Programs are input
input through
through the
the RS-232C
RS-232C interface,
interface, 3.5-inch
USB, keyboard or unit,
floppy disk Ethernet connection.
keyboard The
or Ethernet
conversational
connection. Thecontrol provides Automatic
conversational Strategy,
control provides which automatically
Automatic provides
Strategy, which the cutting
automatically conditions
provides the
and offset
cutting amountsand
conditions in the program
offset afterinthe
amounts theoperator
programanswers a few
after the questions.
operator Thea computer
answers then comes
few questions. The
up with the
computer most
then suitable
comes technology
up with the mostforsuitable
that job. The machine
technology hasjob.
for that stored
Thecutting
machineconditions andcutting
has stored offset
amounts for
conditions cutting
and offsettool steel, graphite,
amounts aluminum,
for cutting carbide,
tool steel, PCD
graphite, and manycarbide,
aluminum, other materials.
PCD and many other
materials.

-8-
Power Supply

Cutting speeds have remained fairly consistent over the last ten (10) years. When wire EDM machines
were first introduced in the United States, they cut at less than one square inch per hour. ONA’s wire
EDM’s today are rated in the mid-thirty square inches per hour (eroding hardened D-2 steel.) Faster or
slower speeds are obtained depending on the workpiece material, thickness, wire diameter and type of
wire used.
The Expert Erosion System is yet another improvement that modify’s the programmed parameters of the
power supply to ensure optimum machining performance. By sensing changes in the workpiece
thickness, flaws or voids in the workpiece material, large tapering and poor flushing conditions, it
automatically adapts to these conditions without operator assistance. With these improved adaptive
control capabilities, wire breakage is reduced to a minimum, making today’s machines far more
“forgiving” and more efficient than in the past.

Another standard feature is advanced corner control, that results in high precision and quality of corners
and small radii.

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Also standard is the anti-electrolysis circuitry that prevents the risk of electrolysis while cutting workpieces
that are in the machine for extended periods. This AC circuit also eliminates the blue discoloration that
appears when cutting titanium alloys with standard circuits and is a beneficial feature when cutting
aluminum. (See Figure 2.)

With EF Circuit Without EF Circuit

Figure 2

Surface finishes on steel parts today are around 45 Ra for the roughing operations and finishes better
than 10 Ra are achieved with multiple skim passes. In many cases, this eliminates or minimizes
“benching”, hand polishing, or lapping parts that have fine finish requirements.

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 Mechanical Section
Table movement

Machine movement is accomplished with massive precision ball screws with recirculating ball bearings
on all axes. They have a double nut construction that is supported on both ends to maintain rigidity.
Glass scales are incorporated on all five axes to ensure accurate positioning and provide optical
feedback. Before shipping, the machine’s position is also checked with a laser interferometer.

Machine Construction

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Wire Path

When wire EDM was first introduced, copper wire was used because it conducted electricity the best.
The low tensile strength of copper wire caused wire breaks when too much tension was applied. There is
a vast array of wires to choose from with brass wire normally being the first choice however, thick or thin-
layered composite wires are available and molybdenum, tungsten, and others types are used for different
applications.

Zinc coated or layered wire are needed for optimizing maximum cutting speeds, soft brass wire is used
when cutting large tapers, high tensile strength wires is needed when using small diameter wires and
good flushability wire helps when cutting thick workpieces.

ONA machines use wire that ranges from .004 inch diameter through .013 inch diameter with .010 inch
being the most commonly used. The wire originates from a supply spool, (weighing up to 100 lbs. on the
A - Series) and then passes along rollers and through a tension device (different diameter wires require
KE-Series)
different amounts of tension to keep it straight). It then passes through the automatic wire threading unit,
and into the upper flushing nozzle, comes in contact with power feed contact where the electric current is
applied. The wire then passes through a set of (upper and lower) round, high precision diamond guides.
It is then directed towards the rear of the machine and into a wire chopper that cuts the wire into small
fragments, and is disposed of in a waste bin. The wire can only be used once, because it also becomes
eroded from the EDM process, and is no longer accurate. The used brass wire is sold to the scrap dealer
for recycling.

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Automatic Wire Threading (AWT)

The demand for dependable and reliable automatic wire threading (AWT) has been met with new and
improved designs. Automatic wire threading is a standard feature on all ONA wire EDM’s. This feature
allows multiple openings to be cut in workpiece automatically and
unattended. Multiple jobs can be set up and cut overnight or over the
weekend without operator intervention, resulting in higher productivity.

The threading process of the AWT takes place automatically by a command

in the program or if the wire breaks. Should wire breakage occur during
machining, the machine returns to the start point of that opening, re-threads
the wire and moves through the program path to the position it broke, powers
up, and continues cutting as if the wire had never broken.

A - Series uses an annealing process to separate the wire. This leaves

The KE-Series
a sharp needle like point on the end of the supply wire. After annealing, a
narrow jet stream of water then directs the supply wire into the lower
precision guide. The wire then proceeds to the back of the machine where it engages with the wire
chopper and the segments are discarded in a scrap wire bin.

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Advancements in Taper Cutting

All ONA wire machines are equipped with a programmable "Z" axis giving precise control of the upper
guide assembly to ensure accurate tapers. The rigid U and V axis is positioned away from the work area
to avoid moisture, contamination and deflection from the high-pressure flush. These axes provide
movement to the top portion of the wire to produce taper angles of up to +/- 30 degrees. Both conical and
oblique cylindrical radii can be programmed, and the size of the top and bottom radii of the part can also
be specified.

Tapering values can be changed within the program. This is useful for
mold applications or form tools that have different side and frontal
taper relief angles. Die blocks are normally machined first with their
taper relief, and then straight cut for their die land. The amount of
taper angle, and direction the wire is tilted in relation to the program
path is in the program.

Independent programming of the U & V axes is for workpieces that have a different shape on the top and
bottom.

The independent, simultaneous movement of all four axes (X, Y, U, V) makes

machining extrusion dies that require a different top and bottom shape to control
the flow of aluminum, rubber and other materials, airfoil shapes, and "squircles"
(a square shape on the top, and a circle on bottom of the workpiece) quite easy.

For small production runs, parts are made by cutting laminated stacks of material;
this is also great for cutting prototype parts

Tapering Examples:

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Dielectric System :

Wire EDM uses deionized water as the dielectric medium compared to Vertical EDM’s that use oil. The
dielectric system includes the water reservoir, filtration system, deionization system, and water chiller
unit. During machining, the dirty water from cutting is drained into the dirty, unfiltered side of the dielectric
reservoir, where the water is then pumped and filtered to 3 microns through a mineral bed vessel, and
returned to the clean side of the dielectric tank. When the vessel approaches its capacity and reaches a
set pressure, the unit automatically back flushes the material (swarf) into a separate decant tank, where
the material decants (settles) in the water.
This is an exclusive ONA patented maintenance free, lifetime filtration system. You never have to
purchase paper filter elements or worry about their disposal. This equates to tremendous cost savings
per year.

Following filtration, the clean water is measured for conductivity, and if required, automatically passes
through a vessel that contains a mixed bed of anion and cation beads. This mixed bed resin (ion
exchange unit) controls the resistivity of the water to set values.

Note: Deionized water is an efficient insulator. Untreated water is a conductor and would cause unstable
cutting, wire breaks and not be usable in the EDM process. The clean, filtered water now flows into the
clean side of the dielectric reservoir and proceeds to the
cutting area. Used water is drained and returned to the
unfiltered, dirty side of the dielectric reservoir to complete
the cycle. A water chiller is also provided as standard
equipment to keep the dielectric, workpiece, worktable,
control arms, and fixtures thermally stable.

The quality of the water is constantly measured. During

the cutting process the chips from the material that is
being eroded, gradually change and increase the water
conductivity level. When this level becomes too high, the water is automatically directed to pass through
the deionizing resin.to bring it to the correct level. Resistivity levels of the water are set at the control
according to the cutting requirements of the workpiece material being machined.
Another additional cost savings and benefit ONA provides is their patented “EKOADD”. By using this
additive, the polarity of the eroded particles in the dielectric are “neutralized” causing them to cling and be
joined together. This additive extends the life of the resin by 50% or more, and also helps clean the
precision guides and power feed contacts while providing cleaner water.

- 15 -
Submerged Machining

Submerged machining is extremely useful for applications that generally have poor
flushing conditions. Some examples would be cuts that require large taper angles, skim cutting tall
workpieces, laminations, tubes, irregular shaped parts, cutting near the edge of a workpiece and parts
with undercuts or thru holes.

Wire machines without submersion capabilities can also cut these types of parts, but with poor flushing
conditions, the power is generally reduced to the wire to help prevent wire breakage, which translates into
slower feedrates for that job. Applications where poor flushing conditions exist are numerous. The
following examples might exist on any given job.

Starting a cut from the edge of a workpiece

When starting a cut from the edge of a workpiece, cutting a form tool,
slicing a tube, bar stock, or starting a cut from a large diameter start
hole, this a slower process without submerged machining capabilities.
There is a greater risk of breaking a wire if the flush is not set properly,
where it deflects away from the wire, and allows the wire to be exposed
to the atmosphere, or if too much power is used. These poor conditions
are greatly reduced when cutting the part submerged.

Laminations

When cutting laminations for production runs, or parts that have slots, cross holes or existing openings in
them, splash flushing machines greatly reduce machining performance. This is because air pockets are
common, and if the wire is exposed to the atmosphere, it
usually results in wire breakage. Submerged machining
provides stable cutting on these type of applications because
the part is submerged, eliminating these air pockets.

- 16 -
Irregular Shapes and Surfaces

When the flushing nozzles can’t be positioned close to the top or

bottom of the workpiece due to the part shape or to clear clamps,
splash flush machines may require constant adjustment of the top
and bottom flush. When machining submerged, these problems are
eliminated.

Cutting Rounds

Cutting round stock or tubing presents a combination of adverse effects. Submerged cutting can
efficiently cut these jobs without the flush being impaired.

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Large Tapering Applications

Many customers that have splash flushing machines recall those jobs they wish they could have
submerged. Skim cuts can be done without fine adjustment to the flush. Splashing, overspray and
dangerous wet floors are almost un-heard of when cutting submerged.

Thermal stability of the entire set-up is enhanced when submerged cutting, thus producing more accurate
skim cuts, better surface finishes, and improved part accuracy.
(A safety interlock is provided on the door, preventing it from being opened until the water is drained from
the worktank.)

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Preventive Maintenance

You wouldn't drive your car five years or more without changing the oil. You wouldn't let ten or more
years pass without painting your house. Well, EDM machines need some tender, loving care too. But,
it's not as bad as you might think! Preventive maintenance on your house (painting) takes twenty hours
or more; maintenance on your EDM usually consumes twenty to thirty minutes a week. Clean the rollers,
check the cables, check the wire drive and the AWT. Like rotating tires, conductivity pieces need periodic
rotating or indexing (every 400 hours), resin needs to be changed, water topped off, lubricate the system,

No matter whose EDM system you own, the lack of

maintenance will lead to slower cutting speeds, size
inaccuracy, lines in the part, wire breaks, a rougher
surface finish, and (eventually) a service call.

Documentation is provided with the machines that

include precise maintenance instructions. These
instructions include a list of items requiring
maintenance; directions for performing each routine;
drawings and/or pictures showing locations, exploded
views, etc.; and the recommended time interval for each preventive routine. The CNC will even show an
alarm on the screen when a maintenance item is due and the hours of machining that have accumulated
since maintenance was last performed. It’s that easy.

- 19 -
Application and Machining Examples

- 20 -
Conclusion:
Wire EDM has a broad range of applications that are continuing to grow
Conclusion:
Wire EDM
•Parts with complex has a broad range of applications that are continuing to grow
geometry’s

•Parts
ƒ requiring
Parts “tenths”
with complex tolerances
geometry’s
ƒ Parts requiring "tenths" tolerances
•Parts where burrs can’t be tolerated
ƒ Parts where burrs can’t be tolerated
•Thin
ƒ or or
Thin delicate parts
delicate that
parts areare
that susceptible to to
susceptible tool pressure
tool pressure
ƒ Progressive, blanking, form, trim, fine blanking, and compacting dies
•Progressive, blanking, form, trim, fine blanking, and compacting dies
ƒ Precious metals
•Precious
ƒ Narrowmetals
slots
ƒ Tooling for forging, or injection molding operations
•Narrow slots
ƒ Medical and dental instrumentation
•Tooling
ƒ forhardened
Cutting forging, or injectionsuch
materials molding operations
as carbide, and P.C.D.
ƒ Cutting difficult to machine materials like hastelloy, inconel and titanium
•Medical and dental instrumentation
ƒ Aerospace, defense, and electronic parts
•Cutting
ƒ hardened
Prototypes partsmaterials such as carbide, and P.C.D.
ƒ Production parts
•Cutting difficult to machine materials like hastelloy, inconel and titanium
ƒ Form tools and inserts
•Aerospace,
ƒ Solid partsdefense, and electronic
that require parts
through openings
ƒ Electrodes (graphite or copper stick electrodes) for vertical EDM
•Prototypes parts

The •Production parts

above list of application represent only a fraction of areas where wire EDM is being used. Other
applications where wire EDM will have tremendous value are still out there waiting to be discovered.
•Form tools and inserts

"The•Solid partsprocess
Wire EDM that require through
is only limitedopenings
by your imagination!"

•Electrodes (graphite or copper stick electrodes) for vertical EDM

The above list of application represent only a fraction of areas where wire EDM is being used. Other applications
where wire EDM will have tremendous value are still out there waiting to be discovered.
ABOUT THE AUTHOR
“The Wire EDM process is only limited by your imagination!”

Don Moulton is a regional sales manager for ONA America. His experiences over the last quarter of a
century include many facets of EDM including applications, management, marketing, sales, and over 15
ABOUT
years THE AUTHOR
working directly for EDM manufactures while promoting EDM throughout the United States and
At the time of this writing Don Moulton
Canada. He has participated was a
in numerous regional
major and sales manager for
local seminars for ONA
SME,America. His experiences
SPE, NMTBA and servedover the
lastthe
on quarter
EDM of a century
steering include for
committee many facetsPublications
Gardner of EDM including applications,
(Modern management, marketing, sales, and
Machine Shop.)
over 15 years working directly for EDM manufactures while promoting EDM throughout the United States and
Canada. He has tel:
participated in numerous
888-662-3367 major and local
– fax: 937.463.7636 seminars
– email: for SME, SPE, NMTBA and served on the
dmoulton@gosiger.com
EDM steering committee for Gardner Publications (Modern Machine Shop.) Additionally, changes have been
made by ONA EDM USA to update machine names and technologies.

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