1. Efficient Production Capabilities
2. Fast
Turnarounds
3. Reliable
Repeatability
4. Without
EDM--Impossible to Machine
5. Reduced
Costs
6. Stress-Free
and Burr-Free Cutting |
7. Exotic Materials
8. Tight Tolerances and Excellent Finishes
9. Program Files Downloadable
10. Independent Axis Machining
11. EDMing Angles to 45 Degrees
12. Parts for Wire EDM |
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Efficient Production Capabilities |
1. Efficient Production Capabilities
Because of the precision and high-speed of wire EDM machines, manufacturers
are increasingly discovering that many parts cam be more economically
produced with wire EDM, rather than with conventional machining.
At Reliable EDM, the bulk of our work is production EDM.
We had one part that we EDMed practically non-stop for over two years. We made a fixture that holds 32 pieces, and each piece has three cavities. Our submersible automatic-threading machine worked 24 hours a day. |
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Fast Turnarounds |
2. Fast Turnarounds
Since Reliable EDM is the largest wire EDM job shop west of the Mississippi
with over 30 wire EDM machines, we can provide fast turnarounds. In addition, we have a 24-hour shift to help us meet our production commitments. |
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Reliable Repeatability
Video Microscope to 325X |
3. Reliable Repeatability
The constant reliability of wire EDM is one of
the greater advantages of this process. Because the programs are computer
generated and the electrode is constantly being fed from a spool (the wire electrode is used only once), the last part is identical to the first part. The cutter wear found in conventional machining does not exist. In addition, tighter machining tolerances can be maintained without additional cost. |
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Without EDM—Impossible to Machine |
4. Without EDM—Impossible to Machine
As more and more engineers, tool designers, and machinists understand
the wire EDM process, many unique machining processes can be performed that can only be done with wire EDM. To help understand the wire EDM process, visualize a super precision band saw with independent axis on top and bottom cutting any electrical conductive material, even tungsten carbide, with a thin (.012 inch and smaller) wire, cutting tapers up to 45 degrees.
Many parts call for sharp internal corners, as internal hexes and rectangular
shapes. Wire EDM leaves a small radius in a corner: e.g. minimum radius for .012” wire is .007” radius in the corner.
At Reliable EDM we have modified our machines to cut up to 40 inches tall. We also made a special fixture where we can cut a single cavity in a tube up to 22 inches deep. |
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Reduced Costs |
5. Reduced Costs
The high-speed cutting wire EDM machines of today have dramatically
reduced costs for many manufactured parts. The machine shown cuts parts 41 x 52 inches submersed up to 24 inches tall. Manufacturers and machine shops are increasingly becoming aware of the benefits of EDM. Conventional machining leaves sharp edges and often burrs when machined. Radii can be stipulated to eliminate sharp corners without additional
cost. This eliminates a filing or sanding operation.
To be competitive in today’s market it is important to take advantage of every cost-saving procedure available. |
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Stress-Free and Burr Free Cutting |
6. Stress-Free and Burr-Free Cutting
Extremely thin section can be machined because the wire electrode never contacts the material being cut. Wire EDM is a non-contact, force-free, metal-removing process which eliminated cutting stress and resultant mechanical distortion.
Materials cut with wire EDM are totally burr-free, and the edges are perfectly
straight. Thin parts can be stacked and cut without leaving any burrs. We often stack hundreds of stainless sheets together to create burr-free flex elements for high-speed couplings. |
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Exotic Materials |
7. Exotic Materials
Wire EDM can cut carbide, inconel, tool steels, ferro-tic, hastalloy, stellite, titanium--any electrically conductive material hard or soft. In fact, the EDM manufactures use hardened D2 to rate the cutting speed of their machines. Hardened D2 cuts faster than cold roll steel.
What can become a nightmare with conventional machining, does not faze wire EDM at all. |
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Tight Tolerances & Excellent Finishes |
8. Tight Tolerances and Excellent Finishes
The wire path is controlled by a CNC computer-generated program with part accuracies up to +/- .0001” (.0025mm). Dowel holes can be produced with wire EDM to be either press or slip fit. We have a video microscope that enlarges to 325X to measure parts.
The extremely fine finish from the standard wire EDM process often eliminates
the need for grinding or other finishing procedures. For extra fine finishes, we can wire EDM parts with an 8 RMS finish. |
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Program Files Downloadable |
9. Program Files Downloadable
If your parts to be machined are programmed on a CAD system, our software system can accept your AutoCad, DXF, and IGES files. E-mailing these files eliminates reprogramming. |
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Independent Axis Machining |
10. Independent Axis Machining
With our 4 axis capabilities, we can machine parts that are different from the top and bottom. |
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EDMing Angles—45 Degrees |
11. EDMing Angles—45 Degrees
With our EDM machines we’re able to wire EDM cavities up to 45 degrees. |
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Parts for Wire EDM |
12. Parts for Wire EDM
Many parts can be economically produced with wire EDM, such as: precision
gages and templates, keyways, shaft and collet slots, splitting tubes, gears, internal splines, hexes, cams, extrusion molds, punches and dies from one piece of tool steel, short run stampings from stacked material, and many other exotic shapes.
Our machines can EDM parts weighing over 10,000 pounds and up to 36 inches tall. We have built our company by becoming the largest wire EDM job shop west of the Mississippi by providing our customers with quality work, reliable service, at great value. Give the EDM specialists a call. |
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