Complex, fast and fully automated: The art of wire erosion

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Modern EDM machines are built to last longer than 30 years

“A Fanuc wire EDM, for example, requires less than 10% of operator intervention to run a full program. That 10% will be the initial contact to program the machine and set the component. After that, the machine can be left to run all the way through a program without interference. It can even recover and repair itself if the wire breaks.”

Expenses or unexpected halts to production are also kept down by the low running costs and longer lifespans of EDM machines.

Andrew says: “A Fanuc machine runs at approximately £5 an hour. This covers wire, filters, electrodes, resins, etc. The machines are also built to be as eco-friendly as possible, so energy costs are kept to a minimum.”

In terms of service, it’s good practice to regularly replace consumable parts, such as bearings, rather than wait for them to fail. With wire EDM, it’s unlikely that you’re going to need a full service more than once a year because you’re not dealing with the force and impact of traditional, heavy-duty machines, so preventative maintenance is key. Fanuc offers a tailored service to suit each business, but we also do a minor/major service between which you can alternate, depending on how long you’ve had the machine and how long it’s been since you had it serviced.

"Saying this, however, modern EDM machines are built to last. Machines are now 30 years old and still going strong. More modern machines could last even longer. Compare this with the ten-year life expectancy of a typical machine tool, and you can see how much of a saving you could achieve. Furthermore, no matter when you purchased the machine, Fanuc will always supply you with the part you need, so an EDM machine really does last for life." When it comes to implementing automated machining processes such as wire EDM, many manufacturers are concerned that they do not have the skills in-house to do this successfully. For Andrew, a user-friendly interface and training are key:

“Many think EDM is a bit of a black art, but I’ve worked with people who became proficient in a week, despite having little to no CNC experience,” he says. “The key is to work with the machine as much as you can and build your experience – you don’t even need to know any coding because this can be produced automatically.”

Complexity and precision in minimal working time

“Training to build those initial skills also helps. We offer a set schedule or can tailor it to a customer’s needs. The user-friendly nature of the machines means that even someone with no knowledge of CNC can operate the machine to a basic level in a week. After that, it just comes down to practice and experience.”

For manufacturers that are already implementing wire EDM into their processes, the advantages are clear: a complex, precise cut with low running costs and minimal requirements for human intervention. Furthermore, the versatility of these machines means that they can be implemented for a range of uses, from the smallest medical devices to the building blocks of an aeroplane.

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“If it conducts, we can cut it," Andrew says. "By controlling that spark, you’ve got a highly repeatable and precise manufacturing process that will keep you achieving quality output for the next 40 years and beyond.”

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