1. Allows for the Formation of Complex Parts
The use of precisely focused electrical discharges makes it possible to make complex or intricate shapes and patterns. It can make different shapes, such as contours and holes, even on the hardest and the most fragile materials.2. It Doesn't Need Mechanical Force.
Unlike a vast array of fabrication processes that use impact to cut through materials, It leverages thermal discharges to cut through parts. This means that the end product will not be deformed, distorted, or have any side effects of deformation caused by brute force in material removal.3. Cost-Effectiveness
When you use it, you'll not have to use a lot of energy to cut even the most rigid materials. Additionally, you'll reduce material wastage since the process only removes the targeted particles only. Your cutting kerf (cut width) is usually less then 0.015”. Also, you don't need other machines for post-processing since the method delivers precise and accurate cuts.4. Accuracy and Precision
The best part is that your final product will not need to be passed through other processes for them to be complete such as grinding, honing etc. The method delivers high levels of accuracy and precision, especially on the smallest pieces.5. High Tolerance
The other benefit is the fact that you can achieve high tolerance regardless of the material you’re working on. You can easily achieve tolerance of +/- 0.005” with some machines that offer tolerances down to a few microns.Pros and Cons
* Pros
The process allows machinists to create intricate shapes and patterns, which can be quite challenging with most conventional machining methods. It can be used on both hard and relatively soft material without any deformation or distortions. This is mainly because there is no contact between the EDM machine and the material being worked on. The method leads to the production of parts with fine and smooth finishes compared to other fabrication techniques. It requires minimal fixturing requirements as compared to other conventional machines. They are self-threading, meaning that if the wire breaks during the cutting process, the operation can progress almost immediately without any delays.*Cons
Their consumables can be expensive, and experts to operate the machines may be scarce. Although they can be integrated with CNC and Automatic Wire Threading (AWT) capabilities to improve the production speed, they are usually very slow compared to other conventional methods. This machining method can only be used on conductive materials.Common Application
Since it is ideal for creating small delicate items, its application is widely spread. However, it is mostly used in:Blanking punches and extrusion dies.
Automotive and aerospace parts and components
Implantable medical devices
Prototypes proof of concept builds
Small hole drilling on hard and soft materials
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