Aug. 04, 2025
EDM Machining is an electrical discharge reduction manufacturing process and a non-contact processing method that uses thermal energy rather than mechanical force to remove material from the workpiece. EDM is only suitable for conductive materials such as titanium, steel, aluminum, nickel and brass. The processing cost, processing time and debugging equipment cost of EDM are relatively high, but EDM can do the process that CNC milling machines cannot do. The purpose of this blog is to introduce the history of EDM processing, advantages and disadvantages, processing process, type and other information, to provide constructive advice for you to choose the right EDM processing service.
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EDM Machining can achieve precision tolerances in the ± 0.005 mm range, especially suitable for machining complex or fine injection molds and metal parts with sharp internal angles, curves, holes, engraving and other features. EDM is unique in that it does not use sharp tools to remove material like traditional CNC machining. Instead, EDM uses electricity and heat to remove material, which is why it is called EDM. The EDM is operated without physical contact with the workpiece being machined, using electrical discharge close to º C to º C to remove excess parts of the material. Because the material to be cut after processing is stimulated by high temperatures into carbon deposits, immersed in the electric fluid, these particles are safely washed away from the electrode and the surface of the workpiece.
In the 18th century, the British scientist Joseph Priestley discovered that electrical discharge can corrode materials on electrodes, and he continued to use electricity to do experiments, but did not know what purpose to do the experiment, and finally gave up the matter. EDM was invented in the 20th century when two Soviet scientists, B. Lazarenko and N. Lazarenko, used electric currents to process conductive materials. And EDM in the 20th century, the rapid development of science and technology in the era of continuous innovation, EDM process increasingly mature and fine workmanship, at the same time for a variety of very hard materials processing EDM precision can be controlled more accurately, easier to operate.
The second step then uses the fixture to clamp the workpiece, next tests the horizontal state of the workpiece and the spark head, and places the tool on the vertical line slide for accurate positioning. Tools emit sparks when they approach the workpiece without touching it. If the tool is too far from the workpiece, it will not produce sparks. If it is too close, then it is possible that the workpiece may fuse together. When the workpiece level is offset, then the entire workpiece being machined is distorted (the size is also wrong). Generally, the discharge gap should be controlled in the range of 1 ~ 100μm, which is related to the pulse size of the discharge current.
The third step is to start debugging the equipment after the machinist calibrates the position, input the position, size, shape and other information you want to process on the computer. When the program is set up, the EDM spark machine can start working. The molten metal cools rapidly in water to form carbon deposits, which the deionized water will wash away. Carbon accumulation to a certain extent can trigger an early warning system, and too much carbon accumulation can adversely affect the outcome.
Electric discharge machining is one of the four popular processing technologies, and milling, turning and grinding keep pace. In general, it is suitable for manufacturing complex molds with fine cavity characteristics. With CNC milling machining principle is completely different, EDM refers to a certain medium, through the pulse discharge between the tool electrode and the workpiece electrode, the workpiece machining method.
During Sinker EDM, the tool and the workpiece are not in contact, but rely on the pulsed spark discharge continuously generated between the tool and the workpiece, and use the local and instantaneous high temperature generated during discharge to gradually erode the metal material. Because there are visible sparks in the discharge process, it is called EDM. Tool electrode commonly used good electrical conductivity, high melting point, easy to process electrical corrosion resistant materials, such as copper, graphite, copper tungsten alloy and molybdenum. In the process of machining, the tool electrode also has a loss, for less than the amount of corrosion of the workpiece metal, close to no loss. As the discharge medium, the working liquid also plays the role of cooling and chip removal in the process of processing. Commonly used working fluids are: kerosene, deionized water and emulsion, etc., because they are characterized by low viscosity and stable performance.
Wire-cut EDM is a non-contact reduction manufacturing process that uses charged thin wires and dielectric fluids to cut metal parts into the desired shape. Metal workpieces are cut through brass wires with diameters ranging from.004 inches to.012 inches (.10 mm to.30 mm) following a precisely controlled path. The diameter of the wire can be larger or smaller. When energized, the wire quickly rises to the required voltage and corrodes the workpiece through discharge. The resulting debris is cooled by deionized water and washed away. Wire-cut EDM process is not sensitive to the hardness of the workpiece, compatible with tungsten carbide, rare carbide.
The wire-cut EDM process must be carried out in a container filled with deionized water. Depending on the application, the materials of the wire include copper, brass, tungsten, molybdenum, coating (galvanized and diffusion annealed) and steel core wire. It is worth noting that no matter what type of wire, there is only one service life, and only the waste value is left after use. AN-Prototype is investing in five high-spec Mitsubishi and Sodick WEDM machines in with complex parts manufacturing up to mm x mm x 670 mm. As a wire-cutting service specialist, we have experience in manufacturing keyways, gears, splines and other feature parts. Typical tolerances for parts are up to ±0. “.
Drilling EDM is the first EDM technology developed, which is suitable for machining parts with holes smaller than 5mm. Drilling EDM processing is also not limited by the hardness of metal materials. The tool electrode material can be steel, cast iron or copper. An-prototype’s Sodick is a high-speed drilling machine that is widely used to drill and cut holes. Aircraft engines in the aerospace sector and gas turbine blades in the energy production sector, as well as impellers in medical and scientific equipment, need to drill cooling holes. In order to form a layer of cooling air on the turbine blade and blade surface, to prevent it from overheating. The Sodick is one of the perfect solutions when you need to drill very long and straight small holes on workpieces with sloping surfaces that are hard to reach. Drilling EDM allows blind and through-hole drilling, and can drill smooth holes without burrs on parts where CNC milling and turning cannot achieve geometric shapes.
EDM plays an irreplaceable role in the manufacture of key components of chassis and engine structures in the automotive industry, ensuring the safety and reliability of vehicles. In addition, in the field of aviation and aerospace, EDM processing can process high-hardness conductive materials and manufacture parts with complex cavities, meeting the requirements of high precision and high reliability in the aerospace field. At the same time, EDM also plays an important role in industries such as shipping, medical inspection, electronics and mechatronics, providing strong support for the innovation and development of various industries.
It is worth mentioning that the EDM processing not only ensures the quality of the workpiece, but also the surface of the workpiece after processing is smooth without burrs, and there is no need to carry out cumbersome post-processing, which greatly saves labor costs. In addition, EDM is also very suitable for high-volume custom manufacturing needs, such as mold manufacturing and prototyping, providing an efficient and reliable solution for the mass production of enterprises.
High cost: Due to the high tool wear rate, the electrode must be periodically checked and replaced, so the accessories cost of the EDM process is high. At the same time, because the debugging equipment takes a long time, and because EDM is a non-traditional processing method, the time debugging cost and the time cost of processing are also relatively high. While EDM can be costly for small series production, EDM is more cost-effective as production scales up and the increased expenses are spread over numerous components.
High power consumption: EDM is an energy-intensive manufacturing process. Because it relies on constant current, it consumes higher power, which increases costs and has a greater impact on the ecological environment. Therefore, compared with EDM, alternative processing methods that consume less power and have less impact on the environment are becoming the first choice.
Incompatible with non-conductive materials: EDMs are compatible with a wide range of metal materials, including the hardest metals, as long as they are electrically conductive (titanium, steel, aluminum, nickel and brass, etc.). But it’s limited to conductive materials, which means it doesn’t work with any plastics, ceramics, or composites. At the same time, because the metal will expand when heated, this may affect the metallurgical properties of the workpiece, (so the cooling of the processed object is also particularly important).
EDM spark machine, after hundreds of years of development, from the unknown equipment to the important role in the production of drilling, we can imagine how difficult the development process of EDM. Now, what EDM brings us is that complex things can be done simply, and don’t need to be too complicated. In the processing, we can choose according to demand, not only for the pursuit of speed and production, EDM is for the pursuit of high quality and production, which is the original intention of the manufacturing industry, but also the mission of An-prototype.
No matter how many. However, as long as it involves right angles, small holes, precision holes and parts with complex cavities, EDM can be selected, although the cost is high, but compared with CNC machining, CNC is difficult to achieve this processing technology of drilling parts in complex cavities, when we give the time cost to those parts that need to be processed, then we can figure out, We use EDM machining is much more cost-effective than CNC machining. An-prototype is a company with more than 15 years of professional EDM machining and CNC machining experience, and there are many successful cases.
It is recommended to manufacture parts in small batches. A mechanic needs time to debug a machine before machining a part, and once the machine is ready, the same process can control the manufacture of hundreds, thousands of parts, or even more. If you only need one or a few custom parts, the cost will be high. Because the labor cost of trained and skilled mechanics is very expensive. If the number of a part reaches thousands, this will greatly reduce the labor cost shared by a single part, or even negligible. In short, the higher the number of parts manufactured, the lower the corresponding cost will be.
An-prototype quality inspection engineers will use CMM coordinate measuring instrument, secondary element, height vernier caliper, screw plug gauge, screw pin and other professional measuring instruments to test your product again, after the test is completed, the product will be packed and shipped together with the full-size quality inspection report, to ensure that the quality of the product delivered to you is intact, beyond your expectations.
Electrical Discharge Machining (EDM) machines are a cornerstone of precision manufacturing, enabling businesses to produce intricate and high-quality components with unmatched accuracy. With various types and features available, selecting the right EDM machine can be a daunting task. At Saikart Technologies, we aim to simplify this process by offering expert guidance and cutting-edge solutions tailored to your unique requirements. This guide will help you navigate the key considerations and factors in choosing the perfect EDM machine for your needs.
The right tool doesn’t just get the job done; it transforms challenges into opportunities for innovation and success.
Want more information on EDM Services? Feel free to contact us.
The first step in choosing the right EDM machine is understanding the specific needs of your application.
Material Type: Consider the materials you’ll be working with, such as steel, titanium, or aluminum.
Complexity of Design: Determine whether your project requires intricate details or simple cuts.
Production Volume: Evaluate if you need a machine for high-volume production or specialized, low-volume tasks.
EDM machines come in various types, each suited for different applications. Understanding these can guide your decision:
Wire EDM: Ideal for cutting complex shapes with high precision.
Sinker EDM: Suitable for creating intricate cavities and molds.
Hole Drilling EDM: Designed for drilling tiny, precise holes in tough materials.
Modern EDM machines offer a range of features that enhance performance and efficiency.
Automation: Look for machines with advanced automation options to reduce downtime and increase productivity.
Power Supply: Ensure the machine’s power capacity aligns with your operational requirements.
User Interface: A user-friendly interface simplifies operations and reduces the learning curve.
Beyond the initial purchase price, it’s essential to evaluate ongoing costs and efficiency.
Energy Consumption: Choose energy-efficient models to lower operational expenses.
Maintenance Requirements: Opt for machines with minimal maintenance needs to reduce downtime.
Durability: Invest in a robust machine that ensures long-term reliability and cost savings.
A reliable manufacturer or supplier can significantly impact your experience with the machine.
After-Sales Support: Ensure the provider offers comprehensive support, including training and troubleshooting.
Availability of Spare Parts: Check for easy access to spare parts and consumables.
Warranty: Choose a machine backed by a strong warranty for added peace of mind.
Selecting the right EDM machine is a crucial decision that impacts the efficiency, quality, and success of your manufacturing processes. By understanding your needs, exploring machine types, assessing features, and considering long-term operational costs, you can make an informed choice. At Saikart Technologies, we’re committed to providing high-quality EDM solutions and expert guidance to help you find the perfect fit for your business. Let us partner with you to achieve precision, efficiency, and innovation in your operations.
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