At Wagner Machine Company, our in-house wire EDM services and 5-axis milling capabilities give us the versatility to create a wide range of parts. While many projects may seem to be a natural choice for one method or the other, some parts straddle the line between processes. That is where our experience allows us to recommend the most efficient manufacturing method for our customer’s toughest parts.
T
he part we made from the blank in the featured picture could have been milled, but for a low volume project where parallelism and several locating features were critical, wire EDM was chosen as the best option to complete the project accurately. Getting the finishes and tolerances right on a milled part would have probably required some trial and error and possibly a setup part or two. By using the EDM process, we were able to make the part right the first time with a simple mill blank and two extremely accurate EDM operations.
For every project, we carefully evaluate which of our precision machining services will deliver the best results in line with our customers’ priorities. Quantity, material, lead time, part features, and tolerance requirements all influence this decision. Let’s learn a little more about these processes and why these complementary capabilities boost our manufacturing efficiency.
Choosing Between Wire EDM and 5-Axis Milling Services
The line between milling and wire EDM capabilities has become increasingly blurred. Thanks to advances in tooling technology, many parts traditionally manufactured with wire EDM can now be milled. This evolution makes it even more essential to carefully weigh the benefits of each option with our customers.
While CNC milling generally offers superior speed and versatility, wire EDM presents several distinct advantages and can create features that are impossible on a mill:
Processing hard or difficult materials. Wire EDM is not a fast process, but in certain cases it can be faster than milling, especially with hardened steels or other challenging materials, such as Inconel and Hastelloy.
Cost-effective operation. Wire EDM uses relatively inexpensive brass wire to cut any conductive material. It is a reliable process that can run unattended for long periods of time. Sometimes, even if it is slower, it is still more productive and cost effective because of the consistency and reduced labor costs.
Precision and finish. Wire EDM consistently achieves superior surface finishes and holds tighter tolerances, making it ideal for high-precision components.
Intricate features. Wire EDM excels at creating small through-features and nearly sharp internal corners that are difficult or impossible with milling cutters.
Thin-walled parts. Thin-walled parts often suffer from vibration during milling, leading to poor surface finish and tolerance issues. Wire EDM does not put any force on the part which basically eliminates these concerns.
Case Study: When Two Technologies Enable a Complex Part
Our expertise shines through when we combine these technologies in innovative ways to machine “impossible” parts. Our ability to integrate advanced technologies in creative ways helps us consistently optimize processes and deliver high-quality results—inspiring customer confidence.
For instance, one of our customers recently came to us requesting a part that included a grid pattern of diamond shapes on a flat surface. The tungsten based material and narrow channels between the diamonds immediately directed the project towards wire EDM, but we had to hold the part on edge to cut the channels. The pattern created a constantly varying material thickness and poor flushing which are two things that can negatively impact speed and accuracy of the wire EDM process.
Another twist was that the design called for drilled and threaded holes as well as half-diamonds along the edges, neither of which could be done on the wire EDM. These features required detailed milling operations with very small tooling in an exceptionally tough material before and after the EDM operation.
On top of the technical challenges for the EDM and milling operations, the material was extremely expensive so we had to get this part right the first time. We ended up making a test blank from material we had in stock to prove our programs and fixturing before running the actual material. We also tested the thread milling operations in a small corner of the actual material that was going to be left over when making the part. The end result was a good part on the first try!
Partner With Us for Precision Machining Services
At Wagner Machine, our consultative approach covers many in house processes as well as coating, plating, and finishing services from our approved outside vendors. We currently have open capacity for Swiss machining services, and production 3-axis or 5-axis milling. We will thoroughly evaluate your project and recommend the best processes to ensure cost-effective and efficient manufacturing.
Request a quote today and discuss your next project with our precision machine shop!