EDM Technical Reference Library

Technical Reference Burr-Free EDM Machining Guide EDM avoids conventional cutting burrs because there is no shearing tool, but rough discharge, debris, recast, and handling can still affect the edge. A visually clean edge can still have recast, microchipping,… Technical Reference EDM Export Review Basics Start an EDM export review by confirming the material, end use, destination, drawing revision, and required documentation before accepting a restricted or sensitive project. Overusing compliance language slows normal quotations, while ignoring… Technical Reference EDM For Medical Components Medical-component EDM planning links process access to material traceability, clean edges, small features, functional surfaces, and post-process acceptance. Overly broad medical wording cannot replace exact material, drawing, cleanliness, edge, and surface criteria. Technical Reference EDM Machining Process Guide EDM machining is a family of non-contact processes that remove conductive material with controlled electrical discharges. Wire EDM makes through profiles, Sinker EDM makes blind forms, Small Hole EDM makes deep small… Technical Reference What Is Micro EDM? Micro EDM uses very small electrodes and low-energy discharges to produce sub-millimeter holes, slots, cavities, and profiles without cutting force. Its defining limits are electrode wear, micron-scale gap stability, flushing, and metrology.… Technical Reference What Is Sinker EDM? Sinker EDM uses a shaped electrode—typically graphite or copper—to reproduce its form as a blind cavity in conductive material. The electrode never touches the workpiece; pulsed sparks erode the cavity shape across… Technical Reference What Is Small Hole EDM Drilling? Small Hole EDM uses a rotating tubular electrode with pressurized dielectric pumped through its center to drill small, deep holes in conductive material. Rotation helps maintain straightness, and internal flushing clears debris… Technical Reference What Is Wire EDM? Wire EDM cuts a programmed through profile with a continuously moving wire electrode in deionized water. The wire never touches the workpiece, and it must pass completely through the material from an…

Technical Reference EDM Vs CNC Machining EDM and CNC machining are complementary: EDM removes conductive material by spark erosion without cutting force, while CNC removes material with contacting tools. Choose CNC for open geometry, fast bulk removal, nonconductive… Technical Reference EDM Vs Laser Cutting The EDM-versus-laser decision should be made feature by feature, not from part size alone. Move open sheet contours and high-volume blanking to laser cutting when speed outweighs the tighter EDM edge requirement. Technical Reference EDM Vs Waterjet Cutting EDM offers tighter detail and hardness independence; waterjet cuts a much wider material range without a heat-affected zone. Choose waterjet for thick plate, nonconductive material, large outlines, and fast rough profiles where… Technical Reference Wire EDM Vs Laser Cutting Wire EDM prioritizes profile accuracy and edge quality; laser cutting prioritizes speed on suitable sheet and plate. Choose laser cutting for fast sheet production when the tolerance, taper, and heat-affected edge are… Technical Reference Wire EDM Vs. Sinker EDM Wire EDM and Sinker EDM solve different access problems: moving wire for through profiles, shaped electrodes for blind cavities. Choose Sinker EDM for blind pockets, ribs, mold cavities, and internal forms; a…

Technical Reference EDM Electrode Materials Guide Electrode material is selected from cavity size, detail, finish, current density, wear, machining effort, and shop handling. A material that roughs quickly may chip at fine edges, while a fine-detail electrode may… Technical Reference EDM For Aluminum Aluminum alloys cut efficiently by EDM, but high conductivity, soft edges, oxide, distortion, and corrosion protection affect setup and finishing. Soft stock can mark or move, and high flushing or heat input… Technical Reference EDM For Carbide And Hard Metal Carbide and conductive hard metals can be EDM machined, but brittle edge chipping, cobalt-binder response, subsurface damage, and recast control dominate the plan. Aggressive roughing can chip edges or damage the binder… Technical Reference EDM For Hardened Steel Hardened steel is where EDM often has the clearest advantage: the process cuts without tool deflection or hardness-driven cutting force. Hard thin walls can move after material removal, and high-energy discharge can… Technical Reference EDM For Inconel And Nickel Alloys Inconel and nickel alloys are good EDM candidates because hardness and work hardening do not create cutting force, but fatigue and thermal surface condition need attention. Low conductivity and heat-resistant composition can… Technical Reference EDM For Stainless Steel Stainless steels are EDM-compatible, but austenitic, martensitic, duplex, and precipitation-hardening grades need different condition, stress, recast, corrosion, and passivation planning. A smooth surface can still contain recast or a heat-affected condition that… Technical Reference EDM For Titanium Titanium is conductive and EDM-compatible; the main planning issue is thermal surface integrity rather than cutting hardness. Aggressive discharge can leave recast or microcracks on fatigue-critical surfaces, while thin sections still need… Technical Reference EDM For Tool Steel Tool steels are strong EDM candidates in hardened condition, especially for punches, dies, inserts, ribs, and wear details that are difficult to cut mechanically. Residual stress, edge microcracking, recast, and corner damage…

Technical Reference EDM Surface Finish Guide EDM surface finish follows discharge energy and finishing-pass strategy; roughness must be assigned to named functional faces. A low Ra value increases cycle time and does not by itself prove recast, edge,… Technical Reference EDM Tolerance Guide Assign the tightest EDM tolerance only to dimensions that control fit and function. Select the process first, then plan finishing passes, thermal stability, datum control, and measurement capability. A global tight tolerance… Technical Reference Sinker EDM Surface Finish Guide Sinker EDM finish is controlled by rough and finish electrodes, discharge energy, orbit strategy, wear compensation, and cavity flushing. A low Ra target can require additional electrodes and time, while electrode wear… Technical Reference Sinker EDM Tolerance Guide For Sinker EDM, assign tolerance to the cavity walls, ribs, floors, and depths that control function. Plan electrode wear, orbit strategy, discharge gap, flushing, datum control, and inspection together. Deep narrow cavities,… Technical Reference Small Hole EDM Tolerance Guide For Small Hole EDM, assign tolerance to the hole diameter, position, straightness, angle, and breakthrough condition that control function. Plan electrode wear, flushing, true path depth, datum control, and measurement together. A… Technical Reference Wire EDM Skim Cut Guide Use skim cuts to improve size, texture, and edge quality after rough cutting. One skim pass does not guarantee Ra 0.4 μm or complete white-layer removal on every material and section height.… Technical Reference Wire EDM Surface Finish Guide Wire EDM finish improves as discharge energy is reduced through one or more trim passes after the rough profile is established. Each trim pass adds cycle time and changes the final profile;… Technical Reference Wire EDM Tolerance Guide For Wire EDM, assign the tightest tolerance only to through-profile dimensions that control fit. Plan wire path, kerf compensation, guide alignment, trim passes, datum control, and measurement together. Extra trim passes add…

Technical Reference EDM Micro Cracks Guide Microcrack acceptance must be tied to material, surface function, discharge history, inspection resolution, and sampling location. A vague “no micro cracks” note without method or magnification cannot be released or verified consistently. Technical Reference EDM Recast Layer Guide Recast always forms during EDM, but its service risk depends on the face. Fatigue, sealing, wear, corrosion, contact, and coating surfaces need a separate decision from Ra; noncritical edges may not. Technical Reference EDM Recast Layer Guide “Remove recast” is not a complete requirement. A release-ready note needs the face, allowable layer or removal rule, method, sampling plan, and post-removal dimension. Technical Reference EDM White Layer Guide The white layer is the visible or metallographically observed resolidified EDM surface; its thickness and continuity vary with energy, material, flushing, and finishing. Assuming every white layer is harmless—or that every part…

Technical Reference EDM Cost Factors EDM cost is driven by setup, cut length or cavity volume, depth or height, pass count, electrodes, material handling, quantity, and inspection—not part weight alone. A whole-part fine finish, unnecessary ultra-tight dimensions,… Technical Reference EDM Design For Manufacturing Guide EDM design for manufacturing starts by routing each feature from access, then assigning tolerance, finish, material condition, and inspection only where they change function. A part designed around one process name may… Technical Reference EDM Quote Preparation Guide EDM quote preparation is the process of turning geometry, material, quantity, quality targets, and inspection into one manufacturable package. Over-tolerancing the whole part or omitting material condition produces a slow, assumption-heavy quote. Technical Reference Micro EDM Design Guide Micro EDM design begins with a measurable feature, a practical electrode, and enough access for stable dielectric flow. Extremely fine electrodes increase wear, breakage risk, cycle time, and uncertainty at the finished… Technical Reference What Drawings Are Needed For EDM Quote? Send a controlled 2D drawing that identifies material, heat-treatment condition, datums, tolerances, functional surfaces, quantity, inspection, and revision. Add a STEP or STP model when geometry is complex; the model shows shape,… Technical Reference What Files Are Needed For EDM Quote? Send a 3D model for geometry and a released 2D drawing for requirements. STEP or STP is preferred for the model; PDF, DXF, or DWG works for the drawing. Missing files or…