Wire EDM
With no physical contact between tool and workpiece, WEDM enables the production of highly intricate geometries, tight tolerances, and hardened components that would be difficult or impossible to achieve using conventional machining methods.
Ultra-precision machining for complex components
Wire EDM or Wire Electrical Discharge Machining (WEDM) is the best in class when it comes to precision and accuracy. It’s so accurate that it removes material through electrical discharge as opposed to using physical cutting tools. At no stage does the machine come into direct contact with the material; if it did, then this would create a short circuit and stop the process completely.
The process works by feeding a thin electrically charged wire through a pre-machined hole (which is completed at the soft machining stage) while sparks jump between the wire and the material. Each of those tiny electrical discharges erodes tiny amounts of the material, which have been pre-programmed and completed to a very high level of precision.
To put into perspective the precision of WEDM, modern systems carefully control wire tension, spark gap, cutting parameters and taper compensation to maintain consistent accuracy throughout the machining process. The machine can even compensate for differences in wire wear as it goes through the piece of metal! All those capabilities build together to consistently enable a 1 micron tolerance throughout all components.
Advanced AgieCharmilles EDM technology & equipment
Brandauer uses the latest George Fisher (GF) AgieCharmilles wire eroding machines which is all backed up with Branduaer’s fully interfaced with the appropriate CAD/CAM software. Brandauer operate two AgieCharmilles GF CUT 3000 machines, an investment that is typical of the firm’s constant drive for precision in every respect. These machines are 1 micron capable, on a long bed CNC table geometry, making high-speed, high-precision, 1,250mm modular tools a reality.
Operating alongside the GF AgieCharmilles CUT 3000s is an abundance of other advanced machinery, including the GF AgieCharmilles CUT E600 for general-purpose EDM machining and the GF AgieCharmilles DRILL 20, often used for drilling starting holes, with an electrode range of Ø 0.1 – 3.0 mm.
WEDM for hard machining
WEDM plays a fundamental role in the manufacturing of Brandauer’s precision tools. Especially the smaller components on the punch and die set. Machining these components requires the material to be in its hardened state, and when combining this material state with WEDM, you get the most accurate setup for machining. These components are the main contacting point in a press setup, so they need to be incredibly hardwearing and precise in their dimensions.
WEDM also allows us to manufacture geometries that would be extremely difficult or even impossible to achieve using conventional machining alone. Complex corners, narrow slots, intricate profiles, and carbide tooling can all be produced with exceptional repeatability and accuracy.
WEDM for components
Brandauer also manufactures components using WEDM. This is done when the tolerance specifications are tighter than conventional machining can achieve or when a full tooling approach isn’t commercially viable.
One main component that takes advantage of WEDM is electrical steel laminations. When manufacturing laminations at lower volumes, investing in a tool and stamping approach isn’t cost-effective for manufacturing, so other methods are turned to.
Conventional lamination manufacturing is done through manufacturing the individual lamination first (the blank), then stacking it into a bonding jig, which then gets bonded together to form the final lamination stack. To manufacture laminations through WEDM. You go through the same process but in reverse. You first need to create the material, as the WEDM process would not be possible using sheet metal. Laminations are made up of hundreds of thin sheets of electrical steel, bonded together to make a final stack. For WEDM, the sheet metal is taken and stacked together to the customer’s specified stack height and bonded together to create a “block” of material. This is then placed into the WEDM machine, where a pre-programmed route is applied, and the machine can then begin cutting the laminations. Once the process is complete, the final parts are already bonded together and in their final form.
There are 2 main advantages when cutting lamination stacks through WEDM. The main being precision. WEDM is the best way to manufacture lamination stacks for precision (comparable to metal stamping), so for low volumes or prototyping, WEDM allows for fully finished components without the need for tooling, whilst also not compromising on precision. The second main advantage being it’s the only method of manufacturing laminations that doesn’t require investing in a boning fixture. Both laser cutting & stamping require investment in an off-line bonding solution as you are blanking the individual laminations out first, through WEDM. As it’s just bonding standard-sized materials, there is no need for a bonding fixture.
Wire EDM machinery & equipment list
Brandauer’s 45,000-square foot facility, allows for over 50 distinct components in production at any one time. With presses operating at 2,000 strokes per minute, you have the potential of millions of components a day at your disposal.
2 GF AgieCharmilles CUT 3000
1 GF AgieCharmilles CUT E600
1 GF AgieCharmilles DRILL 20
1 ACTSpark SP1 Spark Eroder
1 Metaletch ME3000T
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Beyond heritage and case studies, Brandauer has a reputation backed by a range of awards and quality standards. Along with being one of the very few SMEs to hold both the King’s and Queen’s Awards for International Trade and Innovation, the business has also been a proud recipient of multiple awards over the years, all in many different areas, spanning components, people and environmental efforts!
Beyond Brandauer’s success, we hold a range of quality certifications and are committed to continuous improvement of everything we do.
