Wire EDM Services Consolidate Manufacturing Operations to Improve Cost and Lead Time
Wire EDM services have a reputation for being expensive, but this innovative capability can actually yield major cost savings in the right circumstances—especially for parts with strict surface finish requirements.
At Arbiser Machine, we regularly use wire EDM to consolidate multiple manufacturing operations and get our customers the parts they need for less.
How Wire EDM Services Improve Cost and Lead Time
Many customers don’t realize that wire EDM services can be used to achieve high-quality surface finishes on their parts without the need for secondary operations like grinding, buffing, or burnishing. Compared with CNC machining, wire EDM’s ability to produce a finished part without additional steps can save both time and money.
For example, a customer recently requested that we machine and grind a part to achieve a high level of accuracy and a smooth surface finish. The part initially called for extensive milling, welding, and grinding to ensure that it was within tolerance.
But when we examined the part, we determined that we could use wire EDM instead—and consolidate multiple operations into a single step. After obtaining customer approval, we placed the material in the machine, dropped the wire, and walked away.
4 hours later, we returned to a fully completed part, in tolerance and with the appropriate surface finish. Using this single unattended operation reduced labor costs so significantly that we saved our customer close to 50% on this project.
Wire EDM Surface Finishes
If you’re interested in using wire EDM to cut and finish your part, you may be wondering what type of surface finish this capability can achieve:
Precision wire EDM services leverage varying heat intensity to achieve different finishes. At Arbiser Machine, we perform three different kinds of cuts based on customer needs:
First cut. The first cut—typically the hottest—shapes and forms the part. This initial rough cut is capable of achieving a 112 Ra finish, which is the lowest cut quality.
Second cut. For a smoother finish, we’ll perform a second cut at a lower temperature, taking the finish down to 72 Ra. This second cut follows the same path as the first cut to ensure that the part geometry is even more precise.
Surface finish cuts. For the smoothest finish, we’ll perform what we call “surface finish cuts” to massage the surface and bring the finish down even further. We typically aim for 35 Ra, but we can go as low as 9 Ra if needed.
Standard CNC machining operations can achieve similar surface finishes, but if your part is already a good candidate for wire EDM, using this capability can consolidate operations and eliminate post-production costs.
Wire EDM or CNC Machining?
It’s important to note that the savings from wire EDM are part-specific. For small, simple parts or nonconductive materials, CNC machining may be a better option. At Arbiser Machine, we offer a full spectrum of manufacturing services, and we’ll always advise you on the best method to get the job done right.
Want to see if wire EDM services can save you time and money? Request a quote from Arbiser Machine today!