High Precision Cutting with Wire EDM Machines - Advantages and Application Areas’

Tel Erozyon Tezgahları Nedir?

Wire EDM machines are one of the precision machines that perform metal processing by electrical discharge machining (EDM - Electric Discharge Machining). These machines break microscopic particles from the metal surface by generating an electrical discharge. Conductive materials are processed by means of a thin wire. In wire EDM, the cut is made by continuously feeding a very fine wire (usually brass or molybdenum) through a coil and moving it towards the part, generating electrical discharges in the process.

1. Tel Erozyon Kesim Yönteminin Avantajları

• High Sensitivity: Wire erosion offers high precision at the micron level. It is therefore preferred for mould production, gears and cutting parts with complex geometries.
• Insensitive to Material Hardness: It can be used even on very hard materials (such as hardened steels, titanium, carbide), which is an advantage in areas where other cutting methods are difficult.
• Low Mechanical Stress: Since there is no direct physical contact with the material during the cutting process, no mechanical stress is generated on the machined part, which reduces the risk of deformation.
• Fine and Complex Cuts: Wire EDM is capable of extremely fine and complex cuts. This makes it the ideal solution for thin profiles, complex shapes and tight tolerances.

2. Tel Erozyon Tezgahları ile Kesim Uygulama Alanları

• Mould Production: It is widely used in production requiring high precision and complex geometry such as plastic injection moulds, casting moulds, metal forming moulds.
• Automotive Industry: Ideal for the production of gears, engine parts and precision mechanical components.
• Medical Devices: Wire EDM is used in the production of precision medical devices and implants.
• Aviation and Defence Industry: It is preferred for cutting difficult-to-machine materials such as titanium and high temperature resistant super alloys.
• Electronic Components: Wire EDM can be used in the production of semiconductor moulds.

3. Tel Erozyon ile Farklı Kesim Yöntemlerine Göre Üstünlükleri

• Contactless Cutting: Since there is no physical contact, there is no deformation due to abrasion or mechanical stress.
• Thermal Effect Minimum: Compared to other cutting methods, there is less thermal effect on the material, which ensures that the structure of the material is preserved.
• Difficult Machinable Materials: It is more effective than other cutting methods for machining hardened or alloyed materials.
• Cutting Speed and Accuracy: When working with high precision and tight tolerances, it ensures minimum material loss and chip removal.

4. Endüstriyel Kullanımda Ekonomik Faydalar

• Low Material Wastage: Material waste is minimised thanks to high-precision cutting.
• Long Life Cutting Wire: The cutting wires used can last for a long time, which reduces production costs.
• Reduction in Human Resource Requirement: Thanks to CNC-based automation, human intervention is minimal, which reduces labour costs.
• No Extra Processing Required for Complex Parts: There is no need for extra finishing of the cut parts, which reduces costs.

5. Tel Erozyon Kesiminde Dikkat Edilmesi Gereken Faktörler

• Material Quality and Conductivity: It is important to work with high quality, homogeneous and conductive materials.
• Wire Thickness and Tension: The correct selection of the appropriate wire diameter and tension directly affects precision and surface quality.
• Dielectric Liquid Quality: The dielectric fluid used (usually water-based) must not be contaminated and must be kept clean.
• Correct Programming and Setting: Correct programming of the CNC machine affects cutting accuracy and speed.

Wire EDM is a method that offers economic and technical advantages in industries where complex shapes and high precision are required.