The manufacture of parts of complex design is often difficult due to the need to maintain the accuracy of the dimensions of finished products. Most often, this refers to the production of jewelry, automotive parts, tools, etc. In this case, the problem can be solved by using a CNC erosive wire-cutting machine, which guarantees high accuracy and quality of workpiece processing from any metal alloys.

Technical Features and Advantages of Wire EDM Machine

The operation of the equipment is based on the principle of electroerosive machining, when the impact on the surface of the workpiece is carried out not mechanically, but electrically. At the same time, the work efficiency is extremely high, allowing you to obtain high-precision parts with impeccable external characteristics. External defects, including minor ones, are completely absent, and the product does not require additional metalwork and does not need to be controlled by highly qualified specialists involved in work at the final stages of production.

An important feature: only workpieces made of electrically conductive metal alloys are allowed for processing on electroerosive wire-cutting machines. This makes it possible to influence them by the methods of evaporation or melting of the surface layer. The electrode of the machine is a stretched wire located near the fixed workpiece. An electric current discharge passes between the wire and the surface of the part, and the highest possible voltage forms small micron-sized pits on the surface of the workpiece. With the help of water, side traces of erosion are removed, and the metal surface acquires a neat and attractive appearance. A layer of metal a few micrometers deep acquires a compacted structure and increased strength.

At present, the wire-cutting machine is used in the production of stamps, templates, cutters, and other elements. The presence of a CNC system on the equipment allows you to improve manufacturing process and at the same time - to simplify the maintenance of equipment. If you only intend to master a new line of business using a wire-cutting machine, pay attention to second-hand branded models. Their cost is lower, while the working resource remains quite high, and the equipment itself is completely ready for operation and does not require additional adjustment.

Buy an EDM wire-cut CNC machine at a bargain price in the KAMI Association

Branded samples of equipment at an affordable price - this is how you can characterize the offer of our company. Constantly available - a range of machines from leading manufacturers, guaranteeing high productivity and quality of finished products. Our experts are ready to advise you on the order and operation of equipment, as well as offer practical assistance in organizing its repair and maintenance. If necessary, you can use the service of selecting and completing equipment for individual requirements.

Electroerosion is the destruction of metal surfaces under the influence of electric charges on them. This technology is based on the work of Soviet scientists N. I. Lazarenko and B. R. Lazarenko. Using this method, you can easily change the dimensions of metal products, get holes in them of various shapes and depths. Excellent results are obtained by electroerosive machining of profile grooves and grooves, shaped cavities in machine parts and mechanisms. Such equipment for the manufacture of parts from hard alloys where conventional machining is difficult.

Machine tools of the electroerosion type have universal capabilities in the processing of materials with a dense surface structure. This type of material processing compares favorably with other methods of changing the shape and size of parts, since the labor intensity of operations is sharply reduced due to electroerosive technology.

The principle of operation of the EDM machine is shown in the diagram below. Under the action of a pulsed electrical generator, sparks or other electrical interactions are formed in the gap between the electrode and the surface of the part. The space of the spark gap is continuously washed by the coolant flow, due to which the destroyed metal is removed from the treated surface. Under the control of the CNC unit, the process proceeds in a given direction and in the required quantity. Brass wire is most often used as an electrode, which, as it is consumed, is fed into the EDM zone. More modern consumable for electroerosion - molybdenum wire, the consumption of which for the processing of one part is negligible. However, these machines also have significant limitations compared to machines for machining parts. After all, they are suitable for processing only conductive metals and their alloys.

It is possible to influence the metal by electroerosion in various ways: by applying both electric discharges and parametric pulses to the spark gap. Depending on the desired processing result, a more suitable way of its implementation is selected. A very important element of this effect on metal surfaces is that with it it is possible to process the workpiece in different directions at the same time.

Among the methods of electroerosive processing of products, there are:

• electropulse;
• electrospark;
• electrocontact;
• anodomechanical.

Technological operations that are performed by electroerosion include:

• structural strengthening;
• grinding;
• marking;
• cutting;
• fine-tuning;
• bulk copying;
• fine-tuning.

With the help of electrical erosion on these machines, it is possible to make various blind openings, recesses and holes of non-geometric configuration. It is also possible to make threads of any profile on the surface of holes. Machine tools are able to sample metal from the inner surface of products to a given depth, thereby performing operations that replace milling and turning. The technology of electrical erosion is used in the processing of metals that are difficult to classical mechanical machine action. These include, in particular, titanium and its alloys.

To choose which EDM machine to buy, you need to accurately determine the tasks that will be set for this equipment at the enterprise and what operating parameters of the machine will be required to solve these problems. It is quite acceptable to buy a used machine to perform certain technological operations in the workshop, having previously checked its performance. Practice shows that even with a large number of operating hours, EDM equipment is almost not subject to wear.

EDM machines

The methods of electroerosive machining implemented in production can vary greatly depending on the design of the machines, but the principle of operation of the equipment remains the same. Consider the main types of EDM machines used for processing metal blanks.

Wire cutting machine

This machine tool is used for contouring products with high precision and low surface roughness. The workpiece is exposed to an electrode in the form of a molybdenum wire with a diameter of 0.18 mm. The operating costs of this equipment are quite low, since the wire itself is used many times. The traditional EDM wire-cutting machine, which cannot reuse the wire, significantly loses in the cost of similar work operations.

The role of the electrolyte in the working area of ​​the machine is played by the coolant, the flow of which flushes out the erosive products and protects the machined surface of the part from air oxidation. A water-soluble concentrate of a special composition is used as a coolant.

The price of an EDM copier is not very high compared to similar traditional type machines, but its maintenance is very convenient due to the use of a CNC unit. It will take no more than two days to train the operator in the basic methods of working on it.

With this machine you can make:

• various molds;
• stamps;
• gear wheels;
• slotted holes;
• keyways;
• recesses of a complex profile with a depth of up to 20 cm.

The figure above shows a high-speed CNC EDM cutter, which is a jet type and is used for contouring parts. Machines of this type can be used both in the workshops of a small enterprise with piece production of products, and on large enterprises in mass production. The DK 7720 wire EDM machine can currently be purchased for 850 thousand rubles.

piercing machine

The electroerosive copy-piercing machine in a modern design is equipped with a CNC unit, in which the functions of automatic positioning, the orbitality of the movement of parts and the possibility of burning side surfaces are built-in. Also, the machine is equipped with the functions of automatic edge search and search for the center point of the processing zone. Along with this, the programs of the CNC block include the determination of the depth of the cavity and the automatic exit of the tool head to the zero point.

The EDM piercing machine is designed to process both internal and external spherical elements, working along a 3-dimensional linear path. Along with the possible surface treatment along a 2-dimensional arc, it can perform electro-erosion piercing, using the original matrix of the product as an original for copying.

At present, the price of an electroerosive machine of this type fluctuates around 1 million 800 thousand rubles.

Electroerosive machine for cutting metals

EDM wire cutting is used when it is impossible to perform the required cut of a metal part or workpiece using classical traditional processing, when both the cutter and the lathe cutter are powerless in front of the strength of the workpiece. Mechanical cutting is not beneficial or even impossible when it is required to obtain sharp corners with ultra-small radii of curvature inside or outside the part. This situation occurs when machining parts that have undergone hardening or carbide metal joints. Sometimes they also resort to electroerosive metal cutting if, due to the depth or complex structure of the cavity, this is done by a simple mechanical operation on milling machine impossible. Wire-cutting machines complement the set of operations in the manufacture of complex parts of modern engineering.

Electric discharge cutting is an intensive electroerosion of metal in the desired section of the part. The high-frequency pulses generated by the generator are fed to the electrode, which is a molybdenum wire. When the generator is running, the part itself moves in the right direction with the help of an electric drive of the guides of the machine plate. The metal is burned out by electric sparks, and then the destroyed layer is washed off with a coolant of a special composition, which is continuously supplied to the cutting zone. The movement of wire for EDM machines always occurs in the direction perpendicular to the axis of the winding drum.

It is possible to distinguish those technological operations where the operation of electroerosive cutting machines compares favorably with the mechanical processing of metals:

• processing of superhard metals and alloys;
• making cuts in workpieces with angular sharp edges having ultra-small rounding radii;
• processing of cylindrical and shaped surfaces of great depth;
• surface treatment with very high precision.

To program the processing of a part with an EDM machine, you need to have a technical task and a layout of the product itself. The format of the presented data can be any, its translation into commands of the CNC block is carried out by the machine operator or programmer.

In EDM cutting, there is no need to use tools that are harder than the material of the workpiece. For cutting carbide joints, non-ferrous alloy wire is used, which is obtained in the usual way. Equipment for cutting is also not very complex, as well as the technological methods of working with it. The speed of the working process does not depend on the hardness and strength of the material being processed. No effort required for cutting mechanical type owing to what quality of processing turns out very high. The number of various operations and transitions to one processing is reduced to a minimum even with a very complex shape of the part. Various by technical specifications cutting machines have different workflow capacities, but they can all perform similar operations, only in different times.

Models of modern machines

A modern machine for electrical discharge machining of metals consists of the following units:

• electric motors operating independently of each other;
• wire feeder to the erosion zone;
• working bath with coolant;
• desktop for the location of the workpiece in the process of processing;
• machine control unit.

Manufacturers of machines of this type are both Asian and European countries. Having the same purpose, machines from different manufacturers differ greatly in their functionality and price. If Chinese and South Korean equipment is much cheaper than European equipment, then the latter is manufactured by manufacturers for more high level with a greater degree of workflow automation.

ARTA

Russian manufacturers produce ARTA precision equipment for electroerosive machining of metals.

Scientific and industrial corporation "Delta-Test" today is the leader in Russia in the manufacture of equipment of this type. By manufacturing new machines, the company is also engaged in the modernization of equipment of earlier production dates.

Sodick

In the modern equipment market, Sodick is a well-known company that produces wire-cut EDM machines.

Possessing high technological parameters, the equipment of this company is used to process refractory metals and single crystals. With the help of these machines, perforated plates and pipes, working elements of copying machines, stamps with three-dimensional measurement profiles, metal-ceramic stamps are produced. Specialists using such equipment can easily produce cams and their prototypes, electrodes-tools for machines of the copy-and-pierce group.

The Mitsubishi MV1200S wire-cutting machine at a cost of about 7 million rubles allows you to perform the most complex operations for electroerosive machining of parts of any shape made from a wide variety of conductive materials.

With intensive use of this machine tool in modern production, the cost of its purchase pays off in a short time.

Agie

Agie EDM equipment is made in Switzerland and competes with other models of this machine group.

At small overall dimensions on the Agie machine, you can automatic mode perform the most complex work on the processing of hard-alloy products of the widest range.

As can be seen from the article, there are plenty of equipment for electrical discharge machining of parts on the modern market. It is produced by almost all the leading industrial countries of the world under various brands and at different prices. It is not easy to choose from this proposal exactly what our domestic manufacturer needs. However, having measured your financial capabilities and held substantive negotiations with the managers of the companies presented on the Internet sites of this subject, you can draw the right conclusions, and then make the purchase itself.

• Electroerosive wire-cutting machines with CNC Balt-System (Russia) jet type DK77-MS series
• Electroerosive wire-cutting machines of the jet type DK77 series in stock in Moscow
• Electroerosive copy-piercing ZNC machines with a controlled Z-axis series D71 in stock in Moscow
• EDM wire-cutting machines ACCUTEX, Taiwan
• Electroerosive wire-cutting machines of submersible type (СW series) Aristech, Taiwan
• Electroerosive wire-cutting machines of submersible type with automatic wire threading (СW-S series) Aristech, Taiwan
• Electroerosive copy-piercing machine (LS series) Aristech, Taiwan
• Electroerosive piercing machines with CNC (CNC series) Aristech, Taiwan
• EDM Super Drills
• MAXSEE CNC Elevating Bath EDM, Taiwan
• Precision stitching machines NEU-AR
• Electroerosive extractor. Removal of drills and taps by NPP "MEATEK". Available in a warehouse in Moscow.

Electroerosive wire-cutting machines of the jet type DK77 series in stock in Moscow

Price: from $11,500 including VAT

Installation of servo drives on the DK77 series machine.

Electroerosive wire-cutting machines are designed for the manufacture of parts various forms and sizes, such as tools, machine parts, jewelry, dies, gearing, splines, etc. These machines allow you to process parts made of steel of various grades, high-strength composite alloys, titanium, graphite and much more. Models differ in the amount of movement along the axes, the dimensions of the desktop, the type of processing - "single-pass" or "multi-pass". All models of machines are designed to process any conductive materials with high precision and excellent surface quality.

Application area:

When designing machine tools, OOO NPP "MEATEK" took into account the accuracy of processing, ease of operation, labor savings and long service life, which undoubtedly affected the popularity of this equipment and its widespread use in enterprises of various levels. These machines are mainly used in the production of dies and molds, because. accuracy is the main advantage of these models. With only one tool required to get the job done, this machine is your affordable alternative to milling, turning and grinding equipment.

Processing scheme.

Advantages of our equipment:

• Processing of any conductive materials of any hardness.
• No chips (metal melts and evaporates).
• Absence of thermal and mechanical influence on the structure (the surface is not deformed).
• The minimum cut thickness equal to 0.2 mm allows you to effectively save the material being processed.
• The possibility of obtaining parts of complex shape and very small sizes, the production of which by other methods is difficult.
• Processing holes of small diameters and roundings of small internal and external radii.
• Possibility of batch processing.
• Due to the low cost of the machining process and the elimination of the problems of manufacturing expensive punching dies, the machine is the best replacement for punching.
• The possibility of short-term payback of equipment in the presence of problematic parts due to the overall low cost of processing, quick changeover of equipmentfrom one product to another.
• The simplicity of the machine design increases its reliability.
• The presence of a wire drum that rotates in different directions and different speed, thereby providing a rough and finish cut.
• Repeated use of a wire electrode reduces the cost of processing.
• Rational use Supplies.
• Simplicity and clarity of creating complex contours and surfaces using the popular CAM / CAD programs "Compass" and "AutoCAD".

Made in Russia LLC NPP "MEATEK".

Wire-cut EDM machines of the jet type of the DK77 series work on molybdenum wire. Unlike wire electroerosive machines of submersible type of the SV series, jet-type machines of the DK77 series are equipped with an open work table, on which the workpiece is placed for processing without immersing it directly in the working fluid.

Coolant liquid is supplied to the molybdenum wire through a nozzle, directly into the zone EDM, which leads to cooling in the region EDM cutting and leaching of erosion products.

The EDM wire-cutting machine is used for the accurate execution of holes in metals of various densities. The movement of the tool occurs with high precision and smoothness. Engines for it are produced at the enterprise - the manufacturer of machine tools - using a unique technology.

Design

The EDM wire-cutting machine is equipped with plane-parallel motors. To do this, manufacturers create their own neodymium magnets (NdFeB - neodymium-iron-boron). In addition to them, a unique K-SMS control system was also required.

The classic EDM wire cutter is capable of processing only electrically conductive workpieces. Metals are burned by an arc to a considerable depth. A smooth surface remains at the cut site, often not requiring additional processing.

EDM wire-cutting machine helps to obtain complex products: molds, strains, conical and cylindrical surfaces, ledges and bevels. On sale you can find two-coordinate assemblies used for simple operations. More complex products are obtained using five-axis machines.

Principle of operation

In the process of using a wire-cutting machine, brass wire is most often used as a cutting tool. It is performed using a unique technology, and the speed and accuracy of processing depend on its quality.

If high-power pulses are used, which are built into the described machine, the brass wire is equipped with a special coating. Its structure has several layers:

• Base - CuZn40 or brass. Molybdenum, copper can also be used.
• Thermal diffusion layer - zinc concentration over 50%.
• The top layer is pure zinc.

Due to this structure, the wire has a number of advantages:

1. Withstands high temperatures.
2. The arc during processing is stable, the formation of sagging at the cut site is excluded.
3. Reduced wire consumption per cut length.

CNC wire EDM machines are mainly used in serial production. Single products do not justify the purchase of expensive equipment, but some parts can only be obtained with this type of cut. Zinc coating ensures the continuity of the automatic process due to the elimination of shedding of brass from high-frequency currents.

processing process

Electroerosive processing of materials is based on the formation of a spark due to the passage of current high frequency through a minimum air or water gap. This process is most active with the participation of brass.

There are several types of metal processing on the above equipment:

• Copying and stitching technologies.
• Profile-cut.
• Firmware.

More often, wire for EDM machines is attached to a movable assembly. The workpiece is placed on a fixed table. The cutting process is controlled by the CNC system controller, which simultaneously controls several axes.

The essence of technology

An electrical discharge between the wire and the workpiece results in the removal of some of the metal. The separated particles are discharged into the volume of the working fluid. The sludge (crystallizing particles) is filtered out and removed at the end of the cut. The processing speed is regulated by the current strength. But the optimal modes must be selected in which no sagging is formed during the cutting process.

Electroerosion helps to produce products with very thin walls, process soft metals without mechanical damage. This cutting method is used for piercing to a greater depth. The thickness of the wire is minimal, only this parameter limits the diameter of the resulting holes.

Additional processing is not required, since after cutting with current pulses, no burrs remain. It also does not require expensive tools used in classical milling methods. This becomes relevant for workpieces made of viscous materials.

Equipment parameters

CNC process control expands the possibilities of electroerosion metal processing. Deviations of perpendicularity and straightness of movement of the axes are not more than 0.01 microns.

The mechanical accuracy is declared by the manufacturers and no further adjustments are required. The machine is completely ready to start the automatic cycle, you just need to load the model of the part in the standard code.

Modern electronics provide movement accuracy due to angular and linear sensors, the resolution of which is 1.5 microns. The accuracy of the resulting contours varies from ± 1.5 to ± 5 µm over a length of 300 mm.

Characteristics are selected individually according to the needs of production. Based on this, the cost of equipment is formed, focused on a suitable model.

Additional options

The buyer of the machine with electroerosion can retrofit the equipment with the presented options:

• Controlled position of the C axis. More often required for milling cylindrical workpieces.
• Turret with additional degrees of freedom of the tool. With the help of such a model, geometrically complex parts are obtained.
• The table may have additional axes. This option is used when processing case products or several workpieces in one cycle.

The standard package includes systems for cleaning the working fluid, allowing filtration with a quality of up to 3 microns. Dirty cartridges have standard sizes and change fairly quickly.

Modern devices, machines, devices and mechanisms consist of more complex parts when compared with devices that came out earlier. At this stage of technological progress, devices are required to perform large amounts of work. People tend to mechanize everything in order to simplify their daily lives, as well as to achieve new results in research or in areas such as construction, industry, and so on. Along with the complexity of the details, their processing became correspondingly more complicated.

Used to process parts various devices. They differ in the principle of operation, and purpose, and in other aspects. But a huge number of specialists emphasize the advantage of using EDM machines, which designed for processing various parts, and with very convincing results and indicators.

If you need to buy an EDM machine, we recommend that you contact Dominik for advice. The company specializes in the supply and maintenance of EDM machines in Russia and has great experience work with the proposed equipment. Many machines are available, you can get acquainted with the machines at the company's sites in Moscow and Chelyabinsk. The company's specialists carry out the delivery and start-up of equipment, conduct personnel training, provide warranty and post-warranty service, and provide technical support.

The range of the company is presented on the page ‘Electroerosive machines’. You can immediately go to the section you need and get acquainted with the characteristics:

• DK77 EDM wire cutters;
• SCT high-precision servo-driven EDM;
• HQ703 super drill EDM drilling machine;
• Electroerosive piercing machines with one controlled Z-axis.

Purpose of electroerosive machines

Electroerosive machines are used to cut various workpieces that have a wide variety of shapes and sizes. Processing occurs either at a right angle or at an angle from 1 to 30 degrees. The angle at which workpieces are processed depends primarily on the configuration of the machine. The beginning of the cut can occur from the edge of the workpiece, as well as from the inside through a hole that is pre-drilled. Electroerosive machines are designed for the production of parts with an accuracy of 0.015 millimeters.

The main purpose of EDM machines is to replace stamping. Machines of this type Can cut multiple pieces at once, thanks to the possibility of batch processing. In this case, subsequent milling of the part is not required, since during processing there is no surface deformation of the workpiece being processed.

Also, the machine allows you to produce various matrices and templates. One of its great advantages is that it can be easily and quickly reconfigured. In principle, the entire reconfiguration of the EDM machine consists in performing several operations: first you need to download the required drawing from AUTOCAD, then perform several actions already on the computer, then set up the generator and after that you can start processing the next workpiece. Experienced operators spend an average of only 15 minutes setting up the device.

The design of the electroerosive machine

Machines of this type consist of the following units:

Machine bed

This piece is cast iron. Internal stresses are relieved in the chamber. The interior of the bed designed for installation of electrical equipment, since the bed itself has a box type. The working part of the frame is precisely scraped and polished in some places, namely: on the drum carriage, on the column mounts and on the guides of the desktop.

Machine work table

This is a very important component of the EDM machine. The working table consists of two plates, which are mounted on ball-roller guides. Plates are installed one above the other.

If there is a need to move the table, then two stepper motors must be used. This is done using two ball screws. Also you can change the position of the desktop manually, while using the feed wheel, which are all fixed on the same shafts of ball screws.

Wire conveyor

This part of the machine consists of a wire drum, as well as a system of roller guides, which are located in the lower and upper sleeves.

The control computer and generator can be placed either in a rack or in a desktop with a pedestal. The differences are only in the cost of the device, the solidity of the layout, as well as in the design of all equipment.

The principle of operation of the electroerosive machine

After the design aspects of existing EDM machines have been considered above, it is necessary to understand the principle of their operation. It is impossible not to mention that the procedures for processing parts that are used on devices of this type make it possible to achieve simply amazing results.

To begin with, a few words about what electrical erosion is, because, as the reader could already guess from the name of the machine, it is this reaction that underlies the operation of such devices.

The destruction of the upper layer of the surface of the material under the influence of external influences carried out by electrical discharges is called electrical erosion. Exactly this process became the basis for the processing of various materials and parts, which is called electroerosive.

EDM itself is carried out by changing the size, shape, roughness and properties of the surface of the workpiece being machined under the influence of electrical discharges as a result of electrical erosion affecting the workpiece during processing.

Due to the fact that very high temperatures (8000 - 12000 degrees Celsius) operate in the discharge zone, the metal undergoes the following changes: heating, then subsequent melting and even partial evaporation. In order to obtain such high temperatures in the discharge zone, a large concentration of energy is created, which is achieved due to the generator of electrical impulses. The process of electroerosive machining itself takes place in the working fluid, namely in distilled water. It fills the space between the existing electrodes. One of these electrodes is the workpiece itself, and the second is the tool electrode (tubular electrode).

Under the action of the forces that arise in the discharge channel, and also due to the fact that the electrode rotates rapidly, the already liquid and vaporous metal is ejected from the discharge zone into the working fluid surrounding it, and then it solidifies in it with the formation of separate small parts. A hole is formed in the workpiece under the action of a current pulse. Besides, you can observe the waste of the electrode-tool occurring parallel to the formation of the hole.

It should be noted that the tool electrode must necessarily be made of a material with high erosion resistance. Materials that have such important quality and which are able to ensure the stability of the electroerosion process are: tungsten, graphite, aluminum, brass, copper and graphite materials. Usually in such machines copper or brass tubular electrodes are used.

Parameters that affect the speed and accuracy of processing

In order to better understand the operation of EDM machines and influence its quality, you can specify several important parameters, which directly affect the accuracy and speed of the processing process:

In addition to the above parameters, one more can be named, which can also have a great influence on the EDM process. This parameter is the position of the universal cartridge for fixing electrodes, namely, the straightness of its location relative to the X axis. Therefore, the user of the machine it is highly recommended to check the cartridge on a regular basis.

Possibilities of the EDM machine

After all the subtleties of the machining process on an EDM machine have been discussed, we can mention the capabilities of this very useful device with such impressive functionality.

EDM machine:

conclusions

EDM machines are very useful devices that are capable of doing very complex work. A huge number of users who process various materials on machines of this type testify in favor of such equipment, which has proven itself from the best side.

A number of advantages, as well as an atypical principle of operation, which allows you to achieve outstanding results when processing various workpieces, make this processing equipment a real titanium among other types of devices, but also designed for processing various workpieces.

The ease of operation of EDM machines allows them to work even for those users who previously had no experience or certain skills in working with the same equipment.

The principle of operation of EDM machines, which consists in the use of electrical erosion for processing workpieces, allows you to achieve very high quality results.