Wire Electrical Discharge Machining (EDM) is a precision machining process that uses electrical discharges to shape or cut conductive materials. In the wire EDM process, a thin, electrically conductive wire cuts through the workpiece, and dielectric fluid serves as a medium to facilitate the cutting operation.
Historically, deionized water has been the choice for dielectric fluid in wire EDM, whereas oil is commonly utilized in sinker machines. Deionized water plays a crucial role in wire EDM by serving multiple purposes:
- Electrical Insulation: The deionized water acts as an electrical insulator between the wire electrode and the workpiece. It prevents the electrical discharges from occurring prematurely and ensures that the electrical energy concentrates at the desired cutting point.
- Temperature Control: During the wire EDM process, intense heat is generated at the cutting zone due to the electrical discharges. The deionized water cools the cutting zone, preventing excessive heat buildup and maintaining stable machining conditions.
- Flushing Agent: Deionized water also serves as a flushing medium. It carries away the debris, metal particles, and erosion products produced during the machining process. This continuous flushing helps maintain a clean cutting area and improves the machining accuracy.
To optimize wire machine performance, users must maintain the cleanliness of their dielectric fluid at all times. If the fluid becomes excessively dirty, it can lead to rusting of materials inside the tank. This can result in compromised surface finish. Implementing effective maintenance practices involves regularly sending the resin for regeneration and periodically replacing the paper-filter cartridges in the system.
Regeneration is a process that takes ion exchange resin beads that are exhausted (fully loaded), and removes ions that have been picked up during the in-service cycle so the resin can continue to be used. An ion exchange system consists of a bed of resin beads with the ability to pick up hardness or other elements by ion exchange.
DI Regeneration Program
Simply purchase a regeneration coupon from us. Place the coupon with the spent bag, bottle or tank, then mail them to one of the four exchange facilities that represent your state. There the resin will be regenerated and returned to you. As the resin is worn out, it is topped off by virgin resin during the regeneration process.
Overall, the properties of deionized water make it ideal for wire EDM cutting, providing effective flushing, controlled sparking, temperature management, and cleanliness of the deionized water for optimal machining results.