Electrical Discharge Machining is a versatile technology that provides reliable and efficient cutting solutions to machining complex parts with intricate design features and geometries. Sinker EDM and wire EDM are two widely used variants of this technology.
Machinists use these techniques when conventional tools and other machining processes fail to deliver precise and accurate cuts on workpieces to create the desired shape. However, understanding how sinker EDM and wire EDM work and how they differ helps you choose the one that best meets your project’s demands.
This article delves into the sinker EDM vs wire EDM comparison, discussing their working principles and typical applications. Continue reading to learn to choose between these two machining processes for your project!
XTJ is een toonaangevende OEM-fabrikant die zich toelegt op het bieden van one-stop productieoplossingen voor het bewerken van 6061 aluminium van prototype tot productie. We zijn trots op ons ISO 9001 gecertificeerde systeem voor kwaliteitsbeheer en we zijn vastbesloten om waarde te creëren in elke klantrelatie. Dit doen we door samenwerking, innovatie, procesverbeteringen en uitzonderlijk vakmanschap. Toepassingen: automobielindustrie, fiets en motorfiets, deuren en ramen en meubels, huishoudelijke apparaten, gasmeters, elektrisch gereedschap, LED-verlichting, medische instrumenten, enz.
What Does Electric Discharge Machining Mean?
Electrical discharge machining is a non-traditional technique that utilizes an electrically conductive tool electrode made of graphite or copper to cut through metal materials like hardened steel, titanium, tungsten, or carbide. Unlike conventional EDM, it doesn’t require physical contact but creates sparks that can erode the workpiece using an electrical current.
This metal manufacturing process involves using an electrical discharge machine, a dielectric fluid, a tool, and a workpiece. EDM also requires an electric voltage that produces a series of electrical discharges between the two electrodes (the electrode tool and the metal workpiece). These electrodes can never come in contact; hence, they are separated by the dielectric liquid like hydrocarbon oil or deionized water. This distance between the two electrodes is often called the spark gap.
The machinist increases the voltage during the EDM process, causing the dielectric breakdown of the liquid, changing the liquid to an electric conductor. This sudden transition generates an electric arc between the workpiece and the tool in the narrow space. This arc removes material from both electrodes through erosion. Aside from creating the electric arc, the dielectric fluid carries metal debris from the cutting area as it supplies new fluid.
Sinker EDM
Sinker EDM, cavity EDM, ram EDM or volume EDM, is a standard electrical discharge machining process involving immersing a tool electrode and workpiece in an insulating fluid (hydrocarbon oil or other dielectric fluid). The sinker EDM process utilizes pre-machined electrodes – tungsten, copper, or graphite – to create a “positive” of the preferred shape. Then, the electrodes are pressed against the workpiece to form the negative of the actual material shape.
Machinists often regard this process as conventional EDM since it is one of the earliest EDM techniques. Sinker electrical discharge machining creates complex structures/cavities in a workpiece using a positive copy of the preferred shape. For instance, a pyramid-shaped tool is best suited for machining pyramid-shaped cavities in the workpiece.
The shaped tool used in sinker EDM is typically CNC machined from materials including tungsten, copper, or graphite, resulting in increased machining cost and time. Although there are different machining fluids, hydrocarbon oil is the most commonly used dielectric liquid for sinker EDM.
Common Sinker EDM Applications
sinker edm diagram
Sinker EDM Diagram
Sinker EDM is well-suited for making complex cavities. Machinists employ this process to produce hard toolings such as mold and die and fabricate deep ribs. The typical applications of sinker EDM include:
Threads
Medical parts and devices
Rapid tooling
Dies and mold fabrication
Fine details
Blind keyways
Internal splines
Sharp inside corners
Thin and deep ribs
Machining intricate designs in jewelry and precious metals
Benefits and Limitations of Sinker EDM
Precision Cuts, Perfect Finishes
EDM Expert for Your Precision Projects
XTJ is een toonaangevende OEM-fabrikant die zich toelegt op het bieden van one-stop productieoplossingen voor het bewerken van 6061 aluminium van prototype tot productie. We zijn trots op ons ISO 9001 gecertificeerde systeem voor kwaliteitsbeheer en we zijn vastbesloten om waarde te creëren in elke klantrelatie. Dit doen we door samenwerking, innovatie, procesverbeteringen en uitzonderlijk vakmanschap. Toepassingen: automobielindustrie, fiets en motorfiets, deuren en ramen en meubels, huishoudelijke apparaten, gasmeters, elektrisch gereedschap, LED-verlichting, medische instrumenten, enz.
Here are some of the known benefits of the sinker EDM process:
The sinker EDM process doesn’t necessarily require a tool harder than the workpiece.
It is a versatile machining technique that can create highly accurate features and intricate shapes, including inconsistently shaped blind holes, cross sections, thin walls, blind cavities, etc.
It is a low-risk machining process compatible with all conductive metals.
Sinker EDM doesn’t induce stress that may deform the workpiece or cutting tool.
Limitations
The sinker EDM process is ideal for machining conductive materials only. Hence, the technology is incompatible with composites or plastics.
It is time-consuming and costlier than traditional machining processes.
Sinker EDM, unlike CNC machining, is a power-consuming process. The process needs a large amount of electricity to generate adequate energy.
Wire EDM Machining
Wire EDM machining is a non-contact technique that uses thin single-strand electrically charged metal wire with a compatible dielectric fluid to cut a workpiece into various complex shapes. The wire EDM process is sometimes called spark EDM or wire erosion. Like sinker EDM, the workpieces are usually electrically conductive metals and graphite.
EDM machines utilize a thin metal wire between two diamond guides to make precise cut lines by melting or vaporizing the metal workpiece until the wire passes through the workpiece completely. One guide stands above the workpiece while the other sits below it.
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Limitations
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Nauwkeurigheid
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Precision Cuts, Perfect Finishes
EDM Expert for Your Precision Projects
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Conclusie
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XTJ is een toonaangevende OEM-fabrikant die zich toelegt op het bieden van one-stop productieoplossingen voor het bewerken van 6061 aluminium van prototype tot productie. We zijn trots op ons ISO 9001 gecertificeerde systeem voor kwaliteitsbeheer en we zijn vastbesloten om waarde te creëren in elke klantrelatie. Dit doen we door samenwerking, innovatie, procesverbeteringen en uitzonderlijk vakmanschap. Toepassingen: automobielindustrie, fiets en motorfiets, deuren en ramen en meubels, huishoudelijke apparaten, gasmeters, elektrisch gereedschap, LED-verlichting, medische instrumenten, enz.
