Why has precision machining always received so much attention?
Take a submarine as an example. It needs to surface to verify its location after a period of submersion. However, if the gyroscope's support is precise enough, the submarine doesn't need to surface. Such high-precision supports can only be manufactured using ultra-precision machine tools. This demonstrates the importance of precision machining.
Top-tier wire EDM technology and advanced wire EDM machines represent the highest level of technology currently available. The precision of the machined parts is very high, guaranteed to be within ±0.002mm... Enough said, just watch the video and you'll see.
Wire EDM machines are divided into four levels: top-tier, high-end, mid-range, and entry-level.
1. Top-of-the-line wire EDM machine tool
These machine tools can guarantee machining accuracy within ±0.002 mm, with a maximum machining efficiency of 400–500 mm²/min. Surface roughness can reach Ra 0.05 μm, resulting in perfect surface quality with virtually no altered layer. They can perform micro-precision machining using Φ0.02 mm electrode wires. Most mainframes have thermal balancing systems, and some machines utilize oil-based cutting. These machine tools are fully functional, highly automated, and can directly perform precision machining of molds, achieving a mold lifespan comparable to mechanical grinding.
2. High-end wire EDM machine tool
These machine tools feature automatic wire threading, a resistance-free anti-electrolysis power supply, and an overall thermal stability system. They can cut with Φ0.07mm electrode wire with an accuracy of approximately ±0.003mm, achieving a maximum processing efficiency of over 300mm²/min and a surface roughness of Ra<0.2μm. They also have the function of real-time detection of workpiece cross-sectional changes and real-time optimization of discharge power. These machine tools are also widely used in precision stamping die processing.
3. Mid-range wire EDM machine tools
These machine tools typically use a resistance-free, anti-electrolysis power supply and feature immersion machining and tapered cutting capabilities. The practical maximum machining efficiency is 150–200 mm²/min, with an optimal surface roughness of Ra < 0.4 μm and cutting accuracy of ±0.005 mm. They generally use electrode wires of Φ0.1 mm or larger for cutting. The equipped anti-collision protection system prevents damage caused by programming errors or misoperation. An automatic wire threading mechanism is available as an option.
4. Entry-level wire EDM machine tool
This type of machine tool generally uses a process of cutting one and repairing one, or cutting one and repairing two, which can stably achieve a surface finish of around Ra0.8μm and a machining accuracy of ±0.008mm. Most of them can only use electrode wires of 0.15mm and above for cutting, and the microstructure and corners of the machined surface are somewhat different from those of advanced machine tools.
