• Sala de exposición virtual
  • Ubicaciones
  • Acerca de
  • Spanish
    Spanish English
Solicitar presupuesto

TL;DR

Automatic wire threading is the difference between a machine that runs overnight and one that waits for morning. When the wire breaks mid-program, the machine rethreads and keeps cutting instead of sitting idle until someone walks over to it.

If you are shopping for a reliable wire EDM machine with automatic wire threading, the thing to know early is that it works differently from one machine to the next. Threading by hand means emptying the tank before an operator can touch the wire. On a material that breaks wire repeatedly, that repeats every time. Submerged threading skips the sequence.

Sodick’s two submerged systems, Fixed Jet and Super Jet, both thread with the tank full. The difference between them is how each one prepares the wire first. Fixed Jet cuts the wire thermally so it comes away straight, then uses a water jet to carry it through the workpiece. Super Jet does the same and adds an annealing step, heating and stretching the wire before cutting it to a sharp point. An annealed, pointed wire holds its line across a longer unsupported span, which is why Super Jet is matched to tall parts and steep tapers while Fixed Jet is matched to shops restarting constantly across a wide job mix.

Why Automatic Wire Threading Determines Your Uptime Ceiling

Without submerged threading, a wire break means:

  1. Drain the work tank
  2. Raise the table
  3. Rethread the wire
  4. Lower the table
  5. Refill the tank
  6. Wait for the dielectric to stabilize before resuming a precision cut

With submerged threading, a wire break means: the machine rethreads and keeps cutting.

Every step in that first list needs an operator standing at the machine. On an overnight run, none of it happens until someone arrives in the morning, which is why a break at midnight can cost a full shift rather than a few minutes. On a material that breaks wire repeatedly, the sequence repeats on every break.

Sodick’s Fixed Jet and Super Jet at a Glance 

Fixed JetSuper Jet
Full nameFJ (chorro fijo) AWT de alta velocidadRecocido Super Jet AWT de alta velocidad
Standard onALN iGE+, ALP iGE+, and VN Series + AX350LAQ and AP Series
Wire preparationThermal cut, producing a straighter wireAnnealed, then cut to a sharp point
Threading aidWater-jet functionWater-jet function, plus sensor-monitored tension feedback
Submerged threadingYes, with unsubmerged capabilitiesYes, tank stays full
Pairs withClosed guides, which further increase productivityWire guides, plus automatic dielectric fluid level setting
Design priorityFast, repeatable restarts across a high job mixThreading repeatability at larger Z heights

How Fixed Jet Automatic Wire Threading Works

FJ (Fixed Jet) High Speed AWT is our automatic wire threader. It comes standard on the ALC-G Series, the ALN iGE+ Series, the VN Series, and the AX350L.

Fixed Jet is a combined system rather than a standalone threader. It pairs the automatic threading mechanism with the wire guides themselves, and the two work together. Thermal wire cutting and a controlled water jet handle the threading. Closed guides handle the wire capture at either end. The exclusive use of closed guides in combination with the FJ AWT further increases productivity, which is the whole design premise.

Submerged Threading

Fixed Jet threads in both submerged and non-submerged conditions. When the wire breaks, the tank stays up and the machine rethreads where it is, which is what lets an overnight run recover with nobody present.

Closed Guides Multiply the Effect

On machines like the ALN800G iGE+, closed guides are used throughout.

A closed guide captures the wire more completely and more repeatably than an open guide, which means tighter positional control at the moment the threader is trying to land the wire.

How Super Jet Automatic Wire Threading Serves Tall Parts and Extreme Tapers

Our Super Jet Annealing High Speed AWT works the same way Fixed Jet does, with one addition. It threads automatically and threads submerged, working with the wire guides the same way Fixed Jet does. The addition is an annealing step that prepares the wire before threading begins. Super Jet comes standard on our large work area and extreme taper machines, and can be specified on others

How Annealing Changes the Wire

Annealing improves wire straightness, which increases AWT repeatability. The gain is largest at bigger Z heights. A wire that crosses a long unsupported span has more room to wander, and a straighter wire holds its line.

During annealing, the wire is heated and stretched. It is then cut to a sharp point rather than simply parted. A pointed tip requires less wire guide clearance than a blunt one, which improves part accuracy on top of the threading gain.

A sensor in the wire traveling system monitors tensile force and feeds that data back to hold the optimum condition throughout the run.

The annealing AWT threads in submerged mode as well, so the worktank stays full during a rethread, and the Z axis position sets the dielectric fluid level for the operator automatically.

Threading and Tension Through Extreme Tapers and Thick Workpieces

Extreme taper compounds every threading variable. A sample part we cut on the AQ900L runs NAK55 at 7.874 inches thick with a 30 degree taper angle, cut with 0.01 inch wire. On geometry like that, the wire travels a long angled path and lands in a guide offset by the U and V axes.

With Super Jet AWT, tension stability is the other half of the problem. Wire tension is measured just prior to the wire entering the cutting zone, and all adjustments are made automatically at that point. That eliminates tension variation caused by taper cutting. It also removes variation from changing spool sizes, which otherwise accumulates across a long unattended run.

Matching Automatic Wire Threading Technology to Your Part Mix

Find your work below.

  1. High-mix precision work, mostly under 20 inches of Z, where you need fast repeatable restarts across many setups. Look at the ALP iGE+ or ALN iGE+ Series with Fixed Jet. Submerged threading paired with automatic fluid level control unlocks unattended running for this profile
  2. Tall parts with steep tapers, or heavy workpieces. Look at the Serie AQ with Super Jet. The annealing step is what holds threading repeatability as Z height increases.
  3. Proven linear motor performance on a tighter capital budget. Look at the VN600Q, which includes Fixed Jet and an improved surface finish circuit. You keep the threader at the lower price point.
  4. Cemented carbide work with cobalt depletion concerns, or an oil dielectric requirement. Look at the Serie AP, which runs the same Super Jet threader on a fine wire platform. The oil dielectric AP250L machines carbide while eliminating cobalt depletion.

Three Questions to Ask Any EDM Vendor About Threading

Whatever you end up buying, ask these before you sign.

1. Can it rethread submerged, with the tank still up? If the answer involves any version of “it depends,” you have found a limitation that will cost you hours every month. Ask for a demo on a part rather than a bare table.

2. What happens when it has to thread a start hole at maximum Z? Rethreading into an existing kerf is the easy case. Threading a start hole at full Z height is the hard case, and it determines whether your tall work can run unattended. Make them answer for the hard case.

3. Is the threader standard or an option? Then ask what the closed guides cost. A base price with an uptime-critical feature list hanging off it is an incomplete quote.

Threading Is Only Half the Equation

Threading is the first constraint on unattended running. A few others decide whether the program finishes.

Standard equipment on the machines in this article:

  1. Automatic wire tension servo control and automatic voltage regulator. Long cycles expose instability that a short job would hide. Both hold conditions steady across the full run.
  2. Dielectric cooling, plus three-part filtration on our ALP iGE+ and ALN iGE+ machines. Dielectric condition drifts as you cut. Active cooling and filtration keep flushing and thermal conditions consistent from the first hour to the last.
  3. Z-axis automatic fluid level control. Fluid level follows workpiece thickness without an operator setting it.
  4. Thermal Commit (TH COM). Component temperatures are sensed and corrected to minimize thermal displacement from changes in the installation environment and from high-speed driving. On an overnight run in a shop where the HVAC cycles down, that correction is doing steady work in the background.
  5. iGroove+ wire rotation. Our patented wire rotation technology improves surface quality and accuracy while reducing wire consumption by up to 30 percent.

Available as options worth specifying if unattended running is the goal:

  1. Jumbo wire feeders. A 44 pound integrated spool or a 110 pound feeder means wire supply stops being the thing that ends your weekend run.
  2. L-Cut wire chopper. Processes wire for convenient storage, which keeps waste handling from requiring an operator.

We back our flat rigid linear motor driven wire and sinker EDMs with a 10 años de garantía de precisión de posicionamiento, plus a 2-year standard warranty and SodickCare +2 or +4 extended coverage. The drives eliminate backlash and have zero contact, enabling us to guarantee positioning accuracy for a decade after purchase.

If threading reliability is the first step toward unattended machining, automatización is the next one. Single and dual machine solutions supply palletized material and tooling without custom configuration.

Maximize Your Uptime with Automatic Wire Threading

If you want to know which threading system fits your part mix, we can help. Tell us about your typical thickness and taper requirements, along with the unattended hours you are trying to capture. Connect with a Sodick expert and we will walk you through what machine and which AWT matches your job.

Wire EDM has been around since the 1960s, and for the first few decades, non-submerged machining was simply how it was done. The workpiece sat above the fluid line, and two nozzles, one above, one below, sprayed deionized deionized water around the wire to create the dielectric environment needed to cut. It was the only option available, so operators learned to work with it, quirks and all.

Things started to change in the 1980s and 1990s as submerged machining technology matured. Manufacturers began developing tanks that could fully immerse the workpiece, surrounding the entire cut zone in dielectric fluid. The performance advantages were immediately obvious: faster cutting, more stable sparks, less wire breakage, better surface finishes. Shops that made the switch didn’t go back.

Today, non-submerged wire EDM is largely a relic of the past. The last major manufacturer of dedicated non-submerged machines exited the market years ago. Modern machines are built around submerged operation — and for good reason. This article breaks down exactly why submerged machining won out, how the two methods compare head-to-head, and how dielectric oil takes submerged performance into territory that deionized water simply can’t reach.

Why Non-Submerged Machining Became Obsolete

To appreciate the advantages of submerged machining, it helps to understand what operators were actually dealing with on non-submerged machines; it was a fundamentally more difficult process to control.

The Fluid Problem

In a non-submerged setup, dielectric fluid is delivered through upper and lower nozzles that spray deionized water around the wire entry and exit points. The goal was to achieve what machinists called an “umbrella”; a cone-shaped flow of deionized water that kept the spark zone wet while the workpiece sat exposed to air. Getting there required careful balancing of nozzle pressure and position, all at extremely low power settings.

If you got it wrong, you knew immediately. Red sparks — a visible sign that the discharge environment was breaking down due to inadequate flushing — would appear, followed quickly by wire breakage. Some operators wrapped neck strips around the machine head and held them in place with clothespins to help seal the nozzles against the workpiece. It worked, but it was a workaround that revealed a fundamental limitation of the process. The machine was fighting you at every step.

Thermal Instability

Beyond the flushing challenges, non-submerged machining created significant thermal management problems. With only the nozzle spray cooling the workpiece, heat distribution across the part was inconsistent. The area being cut might be adequately cooled, but adjacent areas of the workpiece were exposed to ambient air, creating temperature gradients that caused dimensional drift; particularly problematic on longer cuts or when holding tight tolerances.

In a submerged setup, the fluid surrounding the entire part acts as a thermal buffer, absorbing and distributing heat evenly. This consistency is one of the key reasons submerged machining can hold tighter tolerances with less operator intervention.

Constant Operator Attention

Non-submerged machining demanded presence. Operators had to monitor the umbrella effect continuously, watch spark color, manage power ramp-up carefully, and respond quickly when anything went wrong. Unattended operation, let alone lights-out machining, was essentially off the table. The process simply wasn’t stable enough to run without supervision.

Submerged machining changed the equation entirely. With the fluid environment already established before the cut begins, the machine can run at full power settings from the start, with far fewer interruptions, and less babysitting required.

Head-to-Head — Where Submerged Wins Every Time

The performance gap between submerged and non-submerged wire EDM shows up across every meaningful metric. Here’s how the two methods compare directly.

Comparison Overview

FactorNon-SubmergedSubmerged
Startup timeSlow — requires low-power ramp-up to establish umbrellaFast — full power from the start
Cycle timeLonger — conservative power settings throughoutShorter — higher power, more aggressive cutting
Surface finishInconsistent — flushing variability affects finish qualityConsistent — 7.5 Ra achievable with 1 rough + 7 skim passes
Cutting stabilityProne to wire breakage and spark instabilityStable spark environment throughout the operation
Thermal controlInconsistent — partial cooling creates dimensional driftEven — full immersion buffers heat across the entire part
Operator burdenHigh — continuous monitoring requiredLow — machine handles process autonomously
Lights-out capabilityNot viableFully supported

Job Run Time

The cycle time difference starts before the first spark even fires. In a non-submerged setup, reaching stable cutting conditions requires starting at minimal power and patiently waiting for the umbrella to form and the nozzles to seat properly. Power can only be increased gradually, and a wrong move means wire breakage and a restart.

Submerged machines skip all of that. The tank fills, the part is immersed, and the machine cuts at optimal power settings from the first pass. There’s no ramp-up, no umbrella to find, no spark color to monitor. That difference adds up significantly across a full production run, and compounds even further when reduced wire breakage and fewer interrupted cuts is factored in.

Surface Finish and Precision

Cutting consistency directly drives surface quality, and nothing creates consistency like full immersion. In a submerged environment, every pass of the wire happens in the same controlled fluid environment, with the same flushing effectiveness, the same thermal conditions, and the same spark characteristics. The result is predictable, repeatable surface finishes cut after cut.

On Sodick’s deionized water-based wire EDM machines, operators regularly achieve 7.5 Ra with a single rough cut followed by up to seven skim passes — smooth enough that, at the right angle in the light, you can see a reflection in the part surface. Non-submerged machining, by contrast, introduces variables into every pass: localized flushing variations, temperature differentials, and spark instability that all leave their mark on the finished surface.

Cutting Consistency and Stability

Wire breakage is the single biggest source of unplanned downtime in wire EDM. On non-submerged machines, the conditions that cause wire breakage — inadequate flushing, unstable spark environment, thermal stress on the wire — are baked into the process. Even experienced operators couldn’t eliminate them entirely, only manage them.

Submerged machining dramatically reduces breakage frequency. The wire cuts through a consistent fluid environment on every pass, with reliable flushing and controlled spark intensity. Less breakage means less downtime, fewer resets, and lower risk of surface damage on nearly finished parts. It also results in fewer situations where secondary machining is needed to correct for inconsistencies introduced mid-cut.

Dielectric Oil — When Submerged Machining Needs to Go Further

Deionized water-based submerged machining covers the vast majority of wire EDM work. But for ultra-precision applications and micromachining, dielectric oil fluid unlocks a level of precision that deionized water simply can’t deliver.

Oil-based wire EDM is best understood as the next evolution of submerged machining rather than a separate method. The workpiece is still fully immersed. The process still relies on controlled electrical discharge. But, the dielectric properties of oil change the spark dynamics and make ultra-precision on the first pass possible.

Smaller Spark Gap, Finer Detail

The lower electrical conductivity of oil compared to deionized water creates a smaller discharge gap between the wire and workpiece. A smaller gap means the spark is more precisely localized, which translates directly into finer feature resolution and tighter dimensional control. For parts with intricate geometry, narrow slots, or microscopic features, this distinction is the difference between achievable and not achievable.

Sodick’s AP350L, for example, is purpose-built for fine wire micro machining with dielectric oil, achieving cutting accuracy down to 2 microns; the kind of tolerance that requires specialized measurement equipment just to verify.

Cobalt Depletion Eliminated

Machining carbide with deionized water dielectric causes a well-documented problem: the electrolytic reaction between deionized water and the cobalt binder in carbide gradually depletes cobalt from the workpiece surface, weakening the material and compromising part integrity. This is a critical limitation for tool and die shops working with carbide on a regular basis.

Dielectric oil eliminates this problem entirely. Without deionized water, there’s no electrolysis, no cobalt depletion, and no degradation of the carbide binder. The workpiece comes out with its material properties fully intact — a non-negotiable requirement for high-performance tooling applications.

Ideal for Medical Device Components

Medical device manufacturing represents one of the most demanding application environments in precision machining. Components are often microscopic, features are intricate, tolerances are measured in microns, and there is no margin for error on parts destined for surgical or implantable use.

Dielectric oil submerged wire EDM is built for exactly this work. The smaller spark gap enables feature resolution that deionized water-based machines can’t match. The stable, controlled cutting environment produces the surface consistency that medical manufacturing requires. And because oil doesn’t corrode metal the way deionized water does, finished parts can remain in the tank for extended periods without any risk of surface degradation — critical for shops running lights-out operations where parts may sit overnight before retrieval.

Lights-Out Machining Without Corrosion Risk

With deionized water dielectric, finished parts need to come out of the tank promptly after machining completes. Deionized water causes corrosion on ferrous materials, and leaving a part submerged after the cut is finished risks surface damage that can compromise part quality or require additional finishing.

Oil carries no such risk. A carbide workpiece can remain in an dielectric oil tank for extended periods, nights, weekends, however long, without any corrosion concern. For shops that run unattended overnight shifts, this isn’t a minor convenience. It’s a meaningful operational advantage that expands what lights-out machining can realistically accomplish.

Eco-Cut O: Oil Speed Without the Oil Penalty

One of the historical trade-offs with dielectric oil has been speed. Oil-based machines have traditionally cut slower than deionized water-based machines; a worthwhile trade-off for ultra-precision work, but a real limitation in high-production environments.

Sodick’s Eco-Cut O technology, available on the AP250L, directly addresses this trade-off. Eco-Cut O achieves the surface finish and precision advantages of dielectric oil while cutting up to 12% faster than deionized water dielectric and up to 25% faster than conventional dielectric oil. It speeds up the cutting process by reaching the required accuracy and surface finish in fewer passes — delivering oil-quality results without the penalty of traditional speed.

Sodick Technology Built for Submerged Performance

Whether you’re running deionized water or dielectric oil, Sodick’s wire EDM platform is engineered to extract maximum performance from a fully submerged process.

Tanque de trabajo de subida/bajada de 3 lados automatically adjusts fluid level based on workpiece thickness, eliminating manual fluid management between jobs. The no-drip design keeps the shop floor clean, and the tank can pause at intermediate positions to check progress on thinner workpieces without a full drain.

Fixed Jet Automatic Wire Threader (FJ AWT) supports both submerged and non-submerged threading. Thermal wire cutting produces a straighter wire tip, and the deionized water-jet function improves threading reliability — getting the machine back in cut faster after breaks.

Tecnología iGroove — Sodick’s patented wire rotation system — improves surface quality and accuracy while reducing wire consumption by up to 39%. In high-production environments, that’s a direct reduction in operating cost.

Compromiso térmico (TH COM) monitors the temperature of every machine component and compensates in real time, minimizing dimensional variation caused by ambient temperature changes or extended high-speed operation.

All of this runs on Sodick’s flat rigid linear motor drives — no belts, no ball screws, no backlash — backed by the industry’s only 10-Year Positioning Accuracy Guarantee. Tolerances of ±.0001″ are held reliably, year after year, across the full service life of the machine.

The Bottom Line

Non-submerged wire EDM had its era. For the operators who mastered it, it was a legitimate skill. However, the industry evolved, and the machines that replaced it weren’t just incrementally better, they were a different class of process entirely. Submerged machining delivers faster cycle times, better surface finishes, more consistent cuts, and dramatically lower operator burden. 

And, for the applications that push beyond the capabilities of deionized water dielectric, oil-based submerged wire EDM, particularly with Eco-Cut O technology, opens up a tier of precision that was previously unattainable for most. Micro-components, carbide tooling, medical device parts measured in microns: this is where the industry is heading, and Sodick is leading the charge, spearheading this next evolution.Whether you’re evaluating your first wire EDM machine or looking to upgrade, connect with a Sodick expert today to find out which machine fits your operation.

EDM wire is a critical part of the EDM process, directly influencing cut stability, speed, and surface finish. The type of wire used affects how consistently the cut performs, how efficiently material is removed, and how reliable the process is over time.

This is a comprehensive guide that breaks down the most common wire types used in EDM applications, explains when each is typically used, and answers common questions around cutting hardened materials and wire reuse. The goal is to provide a clear, practical foundation, so you can choose the right EDM wire for your application with confidence.

Why EDM Wire Selection Matters

EDM wire is the electrode that makes the entire process possible. Every electrical discharge that removes material happens between the EDM wire and the workpiece, which means the wire’s behavior directly influences how smoothly and efficiently the cut happens.

The right EDM wire can help:

Using a wire that doesn’t match the application can lead to slower cycle times, inconsistent results, or unnecessary downtime. That’s why wire selection should always be tied to the job at hand, not just price alone.

What Wire Is Used for EDM? A High-Level Breakdown

So, what wire is used for EDM most often?

EDM wire generally falls into three main categories:

While there are many variations within each category, most Wire EDM applications rely heavily on brass and coated wires. Specialty wires exist for niche needs, but aren’t suited for most shops or most jobs. 

Understanding Brass EDM Wire: The Industry Standard

Brass wire is by far the most commonly used wire in the EDM industry, and for good reason.

Brass offers a reliable balance of:

Most brass EDM wire is made from a copper-zinc alloy. Sodick’s brass wire uses a 60/40 ratio, 60% copper and 40% zinc, specifically engineered for optimal performance on Japanese-manufactured machines like Sodick’s Wire EDMs. This higher zinc content delivers better cutting performance on machines designed around this composition, though other manufacturers may use different ratios such as 65% copper and 35% zinc.

One key characteristic you’ll often hear about with brass wire is tensile strength. Tensile strength affects how stiff or flexible the wire is during cutting:

For example, when cutting tapers or parts with varying geometry, a softer wire may be less prone to unwanted bending effects. On the other hand, straight, high-precision cuts often benefit from a stiffer wire that maintains alignment.

For many shops, especially those running general-purpose jobs, brass wire is the go-to choice because it performs well across a wide range of materials and applications without significantly increasing operating costs.

When and Why to Use Coated (Gamma Phase) EDM Wire

Coated wire helps production shops gain efficiency when cutting the same job repeatedly in high volumes. 

Wire EDM coated wires were developed to push performance beyond what standard brass wire could deliver. These wires typically start with a brass core and then receive a surface coating, often zinc-based, through controlled manufacturing processes.

So what does that coating do?

In simple terms, coated wires can:

In production environments where the same part is cut repeatedly, cycle time matters. Coated wires can deliver 10-30% improvements in cutting efficiency compared to brass wire. While coated wire typically costs about $1 more per pound than brass, this performance gain often justifies the investment—especially in high-volume production where increased throughput translates directly to profitability.

Coated wire is also useful when flushing conditions aren’t ideal. For example, if the upper and lower heads can’t be positioned close to the workpiece, debris removal becomes more difficult. Coated wire can help maintain a stable cut in those less-than-perfect setups.

In short, coated wire isn’t about replacing brass wire everywhere, it’s about using the right tool when performance demands it.

Specialty EDM Wire: Application-Driven Options

In some cases, standard brass or coated EDM wire may not be the best fit. That’s where specialty EDM wire comes into play.

Specialty wires are designed for ultra-precision applications that demand exceptional accuracy. In aerospace manufacturing, these wires cut microscopic holes in critical components. In the medical field, they create surgical instruments designed to fit inside blood vessels—parts so small they can only be inspected under a microscope. While specialty wires represent a small percentage of EDM jobs, they’re essential for applications where precision cannot be compromised. 

These wire types are not intended for general use. Instead, they are selected when cutting conditions push beyond what standard EDM wire can reliably handle. They typically cost four to six times more than standard brass wire, but for applications requiring microscopic precision and FDA approval, they’re non-negotiable. 

Can EDM Wire Cut Hardened Steel?

Yes — EDM wire can cut hardened steel, and it’s one of the reasons EDM is so valuable in precision manufacturing.

Because the process relies on electrical discharge rather than mechanical force, material hardness has very little impact on cut capability. EDM wire can be used to machine:

This allows shops to cut parts after heat treatment, helping maintain accuracy and eliminate distortion that can occur with traditional machining methods. While brass wire can handle hardened materials, coated wire is often the better choice for cutting hardened steel. 

Can EDM Wire Be Reused?

In most cases, EDM wire cannot be reused.

During cutting, the wire is exposed to continuous electrical discharges and thermal stress. Even if it appears intact, the wire’s surface and electrical characteristics change as it’s used.

Reusing EDM wire can lead to:

For that reason, EDM wire is designed as a single-use consumable. The cost of fresh wire is minimal compared to the potential cost of scrap parts or machine downtime.

Find the Optimal Wire for Your Job

If you have questions about EDM wire selection, application-specific challenges, or how to optimize your consumables program, connect with an expert today. Our team can help you evaluate your wire needs and identify solutions that support accuracy, efficiency, and long-term cost-effectiveness.

EDM (o descarga eléctrica) son una de las máquinas herramienta CNC más populares. Pertenecen a la clase de máquinas capaces de partir de una materia prima, como un bloque de acero, y fabricar piezas muy complejas con tolerancias precisas y una repetibilidad asombrosa.

Las máquinas de electroerosión se utilizan para muchos tipos diferentes de fabricación de metales y para cortar diversos materiales, desde aleaciones de hierro blando hasta aceros. El proceso de electroerosión en sí es relativamente sencillo, pero hay aspectos que deben tenerse en cuenta antes de decidir si una máquina de electroerosión es adecuada para su taller o negocio.

EDM machines work by using electricity to cut metal

La electroerosión es un método de mecanizado habitual que suele reservarse para materiales difíciles de mecanizar, como aceros endurecidos y superaleaciones. Se utiliza para producir piezas de estos materiales cuando los métodos convencionales son demasiado costosos o poco prácticos.

Las máquinas de electroerosión utilizan electricidad para cortar metal por plasmaSe trata de cargar de electricidad un alambre fino y colocarlo en una bobina llamada electrodo. A continuación, el alambre pasa por la bobina para descargarse en el material que haya que cortar: plástico o acero.

El proceso de electroerosión se basa en una carga eléctrica para crear una chispa que corta el metal. Para ello, la máquina utiliza electrodos o piezas metálicas de las que salen cables.

Los electrodos se colocan en un fluido de corte y se conectan a una fuente de energía eléctrica, normalmente una toma de corriente estándar. La electroerosión funciona colocando la pieza en un baño conductor de la electricidad (llamado electrolito) que contiene iones metálicos. Cuando se hace pasar una pequeña corriente eléctrica a través del electrolito, se crea un campo eléctrico que atrae los iones negativos del material (por ejemplo, el hierro). 

A continuación, un electrodo de alto voltaje creará un arco entre él y su pieza, eliminando esas cargas positivas para dejar espacio a otras más negativas en su pieza, al tiempo que funde su capa superficial. El resultado es un surco circular limpio alrededor de su circunferencia donde antes solo existía material sólido.

Al encender la máquina se crea un circuito entre los electrodos y la tierra (llamado "retorno"). Para que se produzcan chispas, la electricidad debe fluir desde un electrodo a través del fluido de corte y de vuelta a través de otro electrodo, de modo que haya un circuito eléctrico completo entre ellos. Esto ocurre cuando se enciende la máquina de electroerosión: La electricidad fluye de un electrodo a través de la pieza de trabajo (la pieza de metal) y de vuelta a otro electrodo, de modo que la corriente recorre dos trayectorias circulares dentro del metal a la vez.

How fast do EDM machines operate?

Las máquinas de electroerosión son unas de las máquinas herramienta más rápidas del mundo, capaz de cortar hasta 250 pulgadas por minuto. Muchos factores determinan la velocidad a la que funciona una máquina de electroerosión:

The roles of the electrodes in the EDM process are reversed

En el proceso de electroerosión, un electrodo positivo se sustituye por uno negativo y viceversa. De este modo se intercambian los papeles de los electrodos en el proceso de electroerosión. Cuando una corriente eléctrica pasa por el motor, genera calor. El calor hace que el carbono se funda, formando un arco entre el alambre y el electrodo. A continuación, el carbono fundido se aleja de su ubicación original, donde crea la ranura o cualquier otra forma que esté intentando crear en el metal.

El fluido de corte por electroerosión, o fluido dieléctrico, cumple varias funciones durante el proceso. Enfría la pieza para evitar choques térmicos a su paso por la zona de corte. El fluido dieléctrico también limpia la superficie de la pieza, eliminando la suciedad o los residuos que pueda haber en ella.

Si observara de cerca una descarga de chispas entre dos cables, parecería como si estuvieran quemando el material sobrante de un cable sobre otro. Si no hubiera líquido dieléctrico, esto ocurriría inmediatamente y causaría daños a ambos cables (y posiblemente incluso daños a su máquina). El líquido dieléctrico impide que esto ocurra creando una barrera aislante entre los dos cables hasta que se haya producido una acumulación suficiente para que vuelva a fluir corriente a través de ellos.

Dado que el hilo de corte nunca entra en contacto con la pieza durante el proceso de electroerosión, no se añaden tensiones al componente.. Como resultado, se puede utilizar menos tensión para crear ranuras, surcos y ojales en elementos mecanizados mediante electroerosión.

El refrigerante también lubrica ambos cables para que se muevan suavemente uno junto al otro sin atascarse ni sobrecalentarse debido a la fricción causada por una lubricación deficiente. 

El acabado superior de la electroerosión es una de sus ventajas adicionales. Con tolerancias ajustadas, el proceso de corte por hilo produce superficies lisas y sin rebabas. De hecho, la electroerosión por hilo puede utilizarse para crear ranuras pasantes y ojales muy finos para dispositivos médicos, características inaccesibles para los centros tradicionales.

How noisy are EDM machines when operated?

Al comparar el nivel de ruido de una máquina de electroerosión con otros métodos de mecanizado, es esencial recordar que existen muchos tipos diferentes de máquinas de electroerosión en el mercado. Algunas son bastante ruidosas, mientras que otras son mucho más silenciosas. Por ejemplo, se podría pensar que una cortadora de plasma hace mucho ruido debido a todas sus chispas, pero es mucho más silenciosa que un motor eléctrico funcionando a toda velocidad.

Del mismo modo, aunque una máquina de electroerosión utilice electricidad como fuente de energía en lugar de aire a presión, como una fresadora o una fresa (y, por tanto, produzca menos calor), esto no significa necesariamente que sea más silenciosa que estas otras opciones. Depende de lo bien construida que esté la unidad y del tipo de material con el que se trabaje; algunos materiales son más ruidosos que otros cuando se cortan o taladran (por ejemplo, el metal suele ser más ruidoso que la madera). En general, la mayoría de las electroerosionadoras tienden no sólo a producir menos calor, sino que también requieren menos flujo de aire a su alrededor durante el funcionamiento, lo que se traduce en niveles de ruido globales más bajos debido a la reducción de las turbulencias de aire generadas por su acción de corte.

What are the maintenance requirements on an EDM machine?

Las máquinas de electroerosión son más complicadas que otros métodos de mecanizado, por lo que requieren más mantenimiento. Existen recomendaciones de mantenimiento semanales, mensuales y anuales. Estas recomendaciones se encuentran en el manual de la máquina herramienta que se suministra con la máquina.

Como parte del funcionamiento de una máquina de electroerosión, tendrá que limpiarla y lubricarla con regularidad. También es posible que tenga que inspeccionarla y mantenerla con regularidad, así como calibrarla de vez en cuando. Sodick ofrece servicio y mantenimiento para las máquinas que vende. 

How (or when) is an EDM machine better than the alternatives?

En cuanto a precisión, velocidad y facilidad de uso, las máquinas de electroerosión tienen pocos rivales. Las máquinas permiten crear formas complejas, incluso formas que serían imposibles por cualquier otro medio.

En cuanto a lo que no puede hacer una máquina de electroerosión: No sirven para cortar metales blandos como el aluminio o el cobre. Sin embargo, en realidad no están pensadas para esos materiales (de hecho, la mayoría de las máquinas de electroerosión ni siquiera funcionan con ellos).

Lo mejor es consultar a un profesional a la hora de decidir qué máquina le conviene. Las variables que intervienen en la elección de una máquina de electroerosión son el material que se va a cortar, su dureza y la cantidad de material que hay que eliminar. Sodick está aquí para responder a todas sus preguntas.

Un taller mecánico tradicional dispone de muchas máquinas diferentes, algunas diseñadas para una función concreta y otras más adaptables. Un máquina de descarga eléctricao EDM, puede que sea la herramienta más importante de un taller contemporáneo. También conocida como herramienta de mecanizado por chispaUna máquina de electroerosión corta materiales conductores mediante chispas o electricidad. Al eliminar el material, crea cortes utilizando energía eléctrica.

Las electroerosionadoras presentan una tecnología de producción comparativamente innovadora, que es lo que las hace tan singulares. Utilizan la electricidad para desgastar el metal, pudiendo cortar cualquier material conductor. Hay varias tareas en un taller mecánico en las que es preferible utilizar la electroerosión a las técnicas de mecanizado convencionales.

What is electrical discharge machining?

En el mecanizado por descarga eléctrica, el material se erosiona utilizando energía eléctrica. Esa energía genera una serie de chispas de alta frecuencia entre un electrodo de cobre, latón, grafito o tungsteno y aleaciones de cada uno de esos metales y una pieza conductora de electricidad.

Cuando la chispa salta del electrodo a la pieza, el proceso de erosión elimina el material sobrante de la pieza, que es arrastrado por el fluido dieléctrico. El fluido suele ser un aceite específico no conductor o agua desionizada. Es posible obtener acabados extremadamente finos y una precisión de hasta una micra.

La electroerosión se presenta en tres tipos principales: la convencional, también conocida como "sinker", la electroerosión por taladro, y la electroerosión por hilo, también conocida como "WEDM". 

What is wire EDM?

En el mecanizado por descarga eléctrica de hilo, o Electroerosión por hiloEn el proceso de corte, se introduce un hilo metálico delgado de una sola hebra a través de la pieza de trabajo, lo que suele ocurrir en un depósito sumergido de fluido dieléctrico con agua desionizada. Este fluido ayuda a enfriar el proceso y a eliminar el material cortado. El proceso de electroerosión por hilo utiliza corriente eléctrica para cortar materiales conductores, dejando una superficie lisa que no requiere más acabado ni pulido.

Este proceso se utiliza para cortar placas y fabricar punzones, herramientas, matrices, moldes y piezas de cualquier material conductor, incluidos metales duros demasiado difíciles de mecanizar con los métodos tradicionales (como aleaciones metálicas, grafito, carburo y diamante). 

Todo esto significa que una electroerosión por hilo puede programarse para cortar formas muy intrincadas y delicadas. Las propiedades mecánicas de un material apenas cambian en la electroerosión por hilo debido a sus bajas tensiones residuales.

What is EDM hole drilling?

Hay varias ventajas y beneficios Taladrado de agujeros pequeños por electroerosión.

What is sinker EDM?

En platina EDMEn el proceso de electroerosión, una herramienta-electrodo personalizada (a menudo denominada simplemente electrodo) se aproxima a la pieza-electrodo (a menudo denominada simplemente pieza), y una serie de chispas -denominadas impulsos de electroerosión- entre el electrodo y la pieza eliminan material de la pieza mientras el electrodo mecaniza la pieza para darle la forma deseada. 

Moldes, matrices y otras piezas se fabrican con electroerosión por penetración en diversas industrias, como los sectores médico, aeroespacial y de generación de energía. 

When EDM machines are preferable to conventional machining methods

1. They can complete large jobs

En general, las máquinas tradicionales están hechas para funcionar principalmente en situaciones automatizadas, pero requieren mantenimiento. En cambio, las máquinas de electroerosión son menos propensas a errores o interrupciones, por lo que pueden funcionar con poca supervisión.

2. They’re amazingly accurate

Algunas máquinas tradicionales no pueden utilizarse en situaciones específicas, como cuando se cortan esquinas internas afiladas. En el caso de las máquinas de electroerosión, sobre todo las de hilo, no es así. Con el tipo adecuado de hilo, tensión y alimentación, es posible cortar esquinas interiores afiladas y apretadas y, en última instancia, producir diseños que no serían factibles con otras técnicas. 

3. They’re capable of deep cuts

Los materiales que se utilizan con frecuencia en un taller mecánico son difíciles de trabajar por su dureza. A menudo, esto significaba desarrollar diseños que utilizaban cortes poco profundos para reducir la cantidad de esfuerzo necesario para realizar los cortes. Las máquinas de electroerosión pueden realizar cortes más profundos, incluso con materiales muy duros.

Además, estos cortes no causarán costuras ineficaces o problemáticas. En otras palabras, independientemente de la profundidad a la que deba cortar, la herramienta produce un corte limpio y fiable con independencia de la resistencia del material. 

4. They create robust molds

Debido a la capacidad de esta tecnología para cortar materiales sólidos, los operarios suelen elegir máquinas de electroerosión en lugar de máquinas estándar. Mecanizado CNC al crear moldes. 

A veces, para hacer un molde, se emplean dos métodos de mecanizado: primero, se utiliza una fresadora CNC para hacer la forma negativa y, a continuación, se utiliza una electroerosión por hilo para hacer los bordes más precisos. Se trata de un método excelente para crear un molde de inyección. Además, como los materiales del molde acabado son mucho más resistentes, los costes se reducen porque hay que sustituirlos con menos frecuencia. Pero también abre un abanico de posibilidades más amplio de lo que sería concebible con moldes delicados o de un solo uso.

Es posible replantearse por completo el mecanizado y la producción cuando los moldes fabricados por electroerosión se combinan con técnicas de fabricación aditiva.

5. They work best with hard materials

Muchos materiales, incluidos algunos de los más duros del sector, pueden perforarse y cortarse con dispositivos de electroerosión. Incluso cuando cumplen normas estrictas, la dureza apenas influye en la precisión o la maniobrabilidad.

Una herramienta de electroerosión puede cortar eficazmente todos los materiales conductores, incluidos el carburo de tungsteno, el acero endurecido, el titanio, las aleaciones de Inconel e incluso materiales como el Hastelloy, compuesto de níquel y molibdeno. Es casi imposible cortar estos materiales con precisión utilizando técnicas convencionales de corte y mecanizado.

6. They can design a distinctive finish

En efecto, las herramientas de electroerosión pueden crear superficies como cráteres y marcas de viruta en función de la velocidad de corte; esto suele ocurrir cuando el corte es rápido. Esto puede ser una ventaja cuando se modifican distintos parámetros. Por ejemplo, cortar a menor potencia minimiza los defectos y produce una superficie más lisa con un brillo similar al de un espejo.

Los operarios pueden realizar ajustes para mejorar el producto acabado y reducir las etapas adicionales. No se necesitan otras herramientas para obtener el mismo resultado porque se puede conseguir ese acabado de espejo. Esto ayuda a proporcionar un trabajo excelente al tiempo que acelera la producción global.

Better results are available with electrical discharge machining

La tecnología de electroerosión no es perfecta para todos los casos o aplicaciones, ya que no puede utilizarse para cortar materiales como plástico o yeso. Pero el mecanizado por electroerosión ofrece muchas ventajas cuando se trata de materiales conductores duros o metales.

Su empresa se beneficiará de una precisión inigualable y de la capacidad de realizar cortes más profundos y producir bordes más refinados encontrando menos resistencia. Las herramientas de electroerosión pueden funcionar tanto como sea necesario, sin interacción, incluso en una instalación automatizada con "luces apagadas", porque son muy fiables.

Como mínimo, no hay excusa para que su taller de mecanizado no disponga de una (o varias) herramientas de mecanizado por descarga eléctrica. Sodick está a su disposición para ayudarle a evaluar sus necesidades.