Available exclusively in the UK and Eire through Warwick Machine Tools, Excetek’s comprehensive range of wire EDM machines offer world-leading technology and capability at competitive price points that leave competitors struggling to keep up. Backed by continuous innovation from Excetek’s R&D and production teams, the machines are renowned for their high-quality construction and user-friendly NC control system. As a result, new customers often find themselves cutting parts on the very same day their machines are installed – and many return for additional Excetek machines to expand their operations.
So, what is wire EDM and how does it work? “Wire EDM, or electrical discharge machining, is a non-contact subtractive process that uses an electrically charged wire, typically made of brass, and a dielectric fluid to cut complex shapes into metal,” explains Ian Holbeche, Managing Director of Warwick Machine Tools.
He continues: “The process produces small chips and precise cut lines by melting or vaporising the material without physical pressure. This non-physical cutting method makes it ideal for materials that are difficult to machine conventionally, such as soft or flexible components, and is suitable only for electrically conductive materials.
“Machining a part using the process usually involves securing it in a suitable fixturing system and submerging the workpiece into a dielectric fluid, while running the wire through it to produce sparks as it passes an electric current between the wire and the part.
“So, the wire carries one side of the electric charge, and the workpiece holds the other. When the wire nears the part, an intense electric spark jumps the gap, melting tiny sections of the material. In the wire EDM process we can consider the electric spark as the cutting tool to create the desired shape in the material. The process also uses deionized water to flush away tiny metal particles during cutting.”
As an electrothermal cutting process, wire EDM can machine a variety of materials, including all alloys, superalloys (HRSA), and exotics such as steel, aluminium, brass, bronze, copper, carbon graphite, carbon steel, stainless steel, Inconel, and titanium. “The hardness of the material is no obstacle for wire EDM. Whether you are cutting P20 tool steel pre-hardened to 28-32 HRc or grade 2 titanium at 90 HRc, Excetek’s technology can handle it with precision,” says Ian Holbeche. "The same holds true for soft or brittle materials. Since no physical pressure is applied during the cutting process, parts are cut to exceptionally tight tolerances without any risk of distortion or damage," he adds.
With wire diameters ranging from 0.15 to 0.3 mm, wire EDM is especially suited for producing complex and intricate parts with tight tolerances, such as those required in highly regulated industries like medical and aerospace manufacturing. In fact, many manufacturers across these technically demanding sectors rely on wire EDM within their CNC machine shops to achieve the precision and quality required for their most critical components.
Why Choose Wire EDM for Your Machine Shop?
Unique and Complex Shapes: With wire diameters as thin as 0.15 mm, wire EDM excels in cutting intricate and complex shapes that are nearly impossible to achieve using other methods, all with unparalleled precision.
Superior Cutting of Hard Materials: Hard materials like Inconel, titanium, and high-nickel alloys can cause rapid wear on conventional CNC cutting tools. However, wire EDM’s electrically charged cutting process makes it ideal for tackling these tough materials, even cutting through carbide – the very material used to make cutting tools.
Consistency: Wire EDM can run multiple parts simultaneously, even when unmanned, delivering a high degree of repeatability and consistency. Many users operate their wire EDM machines overnight with little or no manned intervention, confident that each part will be identical upon completion.
Tight Corners: The small wire diameter allows wire EDM to produce tight corner radii that would be difficult or impossible for an end mill to achieve. Meeting exact corner specifications is critical for applications like mold making and extrusion plates, where even the smallest errors can lead to significant issues. Excetek machines feature Smart Corner Control, automatically adjusting feed and power to prevent corner "wash-out."
Tight Tolerances and Surface Finish: For parts requiring exceptionally tight tolerances, wire EDM is the solution. Excetek machines can achieve tolerances as tight as ± 3 microns and offer surface finishes as fine as Ra 0.3 microns, further improved to Ra 0.14 microns with the Super Finishing Circuit.
Large Part Capacity: Unlike traditional CNC machines, which may struggle to maintain tight tolerances on large parts, wire EDM handles even large workpieces while maintaining the precision required.
Perfect Fit for Mating Parts: Since wire EDM guarantees such a high degree of accuracy and precision, it is an ideal solution for mating parts that require exact specs for a perfect fit and function for critical assemblies.
The Excetek Advantage
Ian Holbeche concludes: “When conventional machining methods like milling and turning fall short of the precision required, wire EDM provides a superior alternative. Whether your parts need intricate shapes, tight tolerances, or high material hardness, Excetek’s wire EDM machines offer a cost-effective solution. At Warwick Machine Tools, we’re committed to delivering the best in precision machining – talk to us to discuss how our technology can solve your toughest machining challenges.”