Advantages and Disadvantages of EDM

In the quasi religious world of EDM (electronic dance music), Avicii is on par with god himself. However, in manufacturing circles, there’s much more to this technology than a few thumping beats. Manufacturing engineers turn to electrical discharge machining (EDM) when traditional milling, turning and grinding aren’t up to the task. While this is a great solution, it does have some limitations that can sometimes be overlooked.

Unlike other conventional cutting processes, wire EDM doesn’t make direct contact with the work piece. Instead, the tool and work piece are separated by a gap called a spark gap. This allows delicate sections and weak materials to be machined without distortion. It also prevents mechanical stresses from forming between the two components.

Another advantage is that the machining process requires very little material and can produce quality cut end surface finishes that aren’t always possible with other machining methods. This can save time, labor and material costs.

Wire EDMs are capable of machining complex 2D profiles that are impossible with other cutting processes. They can also be used to cut internal corners with very small radii, machine blind and high aspect ratio pockets in extrusion dies and can generate non-round openings or cavities. However, this method is not ideal for long cutoffs of tubing and can be expensive compared to other options. Additionally, it consumes a lot of electricity which isn’t great for the environment.

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