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Technical Application #3 - Electrical Discharge Machining - Wire EDM: The Top Choice for Complex Part Processing4
https://www.herbao.com.tw/en/ HER BAO MACHINERY CO., LTD.
HER BAO MACHINERY CO., LTD. 1 F., No. 10-59, Yuangang, 2nd Neighborhood, Yuangang Vil., Yuanli Township, Miaoli County 35852, Taiwan (R.O.C.)
  Helical Gear Principles and ApplicationsWhy Do Electric Vehicles Rely on Them? When discussing mechanical power transmission, gears are among the most essential components found in almost every type of machinery. Among the many gear types available, helical gears are one of the most common and widely used.From electric vehicle (EV) drivetrains, transmissions, and automation equipment to various industrial machines, helical gears can be found in countless applications. Their widespread use is mainly due to two key advantages: smooth operation and high transmission efficiency.So, what exactly is a helical gear, and how does it differ from other types of gears? What Is a Helical Gear? The most distinctive feature of a helical gear is its angled tooth design. Unlike spur gears, whose teeth engage all at once, the teeth of a helical gear mesh gradually and continuously, much like the action of a zipper.This method of engagement significantly reduces impact and vibration during operation, resulting in smoother performance. For this reason, helical gears are widely used in high-speed applications where smooth and quiet operation is essential. Transmission Principles of Helical Gears Helical gears operate through rolling contact transmission. As two gears mesh together, force is transmitted gradually along the angled tooth surfaces, helping maintain stable power delivery while improving overall transmission efficiency. In simple terms, helical gears offer several key advantages：• High transmission efficiency• Smooth operation• Excellent high-speed performance• Stable power transmission Because of their high efficiency, more of the input power can be effectively transferred to the output side. This makes helical gears particularly suitable for equipment that requires continuous, high-speed operation.  Manufacturing Process of Helical Gears  Although helical gears are among the most commonly used gear types, manufacturing precision remains critical to their performance. Common manufacturing methods include：Gear HobbingGear hobbing is one of the most widely used processes for manufacturing helical gears. It offers the advantages of high production efficiency and stable manufacturing costs.CNC MillingFor high-precision applications, some helical gears are manufactured using CNC milling machines to achieve greater tooth profile accuracy and consistency.After machining, additional processes such as heat treatment, grinding, and precision measurement are typically performed to ensure stable performance during high-speed operation.  How Are Helical Gears Measured and Inspected?  In addition to manufacturing quality, proper measurement and inspection are essential for ensuring the performance of helical gears.Common inspection items include：• Pitch measurement• Tooth thickness measurement• Tooth profile deviation inspection• Transmission error testing    Advantages of Helical Gears  Helical gears are widely used because they provide an excellent balance between efficiency and smooth operation. Compared with other transmission methods, helical gears offer several key advantages：1. High Transmission EfficiencyBecause helical gears operate through rolling contact, they can effectively reduce energy loss during power transmission.2. Ideal for High-Speed OperationTheir smooth meshing characteristics make them particularly suitable for high-speed applications.3. Stable Power TransmissionHelical gears can transfer input power efficiently and consistently to the output side, ensuring reliable performance.  Common Applications of Helical Gears  One of the most common applications of helical gears is in automotive transmissions. Transmissions require high-speed operation, smooth gear shifting, and reliable power transfer—all of which are key advantages of helical gears. In addition, helical gears are widely used in：• Automation equipment• Industrial gear reducers• CNC machine tools• Motor drive systems• Packaging machinery• Conveyor systems  Conclusion: Why Are Helical Gears So Common？ Helical gears have become one of the most widely used transmission solutions in industry because they combine high efficiency, excellent high-speed performance, and stable power transmission.While different gear types each have their own ideal applications, helical gears remain a preferred choice whenever the requirements include high-speed operation, smooth performance, and long-term reliability. ( Related Reading Why Are Robotic Arms So Precise？ Knowledge Sharing No. 12 – Understanding Hypoid Gears: Principles, Advantages, and Applications ) Herbao Machinery will continue to drive technological innovation and provide customers with professional and reliable solutions.If you have any technical questions, please feel free to contact us. We are always happy to help！ https://www.herbao.com.tw/en/hot_534672.html Knowledge Sharing No.14 – Helical Gear Principles and Applications | Why Do Electric Vehicles Rely on Them? 2026-07-22 2027-07-22
HER BAO MACHINERY CO., LTD. 1 F., No. 10-59, Yuangang, 2nd Neighborhood, Yuangang Vil., Yuanli Township, Miaoli County 35852, Taiwan (R.O.C.) https://www.herbao.com.tw/en/hot_534672.html
HER BAO MACHINERY CO., LTD. 1 F., No. 10-59, Yuangang, 2nd Neighborhood, Yuangang Vil., Yuanli Township, Miaoli County 35852, Taiwan (R.O.C.) https://www.herbao.com.tw/en/hot_534672.html
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Home Information Technical Application #3 - Electrical Discharge Machining - Wire EDM: The Top Choice for Complex Part Processing [2025-01-03]

Links：https://youtu.be/nbn5lwEc8og

 

Electrical Discharge Machining - Wire EDM
The Top Choice for Complex Part Processing


 What is Wire EDM？ 
Wire EDM is a thermal process widely applied in the precision manufacturing of parts across various industries. This section delves into the functions of Wire EDM and its role in the manufacturing sector, especially when paired with rotary positioning tables.

 Wire EDM Process 

Also known as EDM or WEDM, Wire EDM is a precise machining method that uses thermal energy to remove material from a workpiece. Known by various names such as spark erosion and wire erosion, the process involves a fine metal wire and deionized water to cut metal and prevent rusting. The wire, usually made of brass or layered copper, acts as the tool electrode and follows a pre-defined path to shape the workpiece.
 History of Wire EDM 

The phenomenon of electrical discharge erosion was first observed in 1770 by British physicist Joseph Priestley, who termed it electrical discharge erosion. In 1967, the Soviet Union developed the first commercially available digital-controlled Wire EDM machine.

 
 Types of Wire EDM 

Wire EDM is categorized into fast wire, medium wire, and slow wire EDM. Fast wire EDM operates at speeds of 6 to 12 m/s, with high-speed reciprocating movement of the electrode wire but lower cutting precision. Medium wire EDM, an evolution of fast wire EDM, introduces frequency control for multiple cuts, a newer process developed in recent years. Slow wire EDM features a wire speed of 0.2 m/s with low-speed unidirectional movement, offering high cutting precision.

Types and Sizes of Wires Used in Wire EDM

Wire EDM uses metal wires with diameters ranging from 0.0008 to 0.013 inches. Thinner wires require lower power settings and cut at slower speeds. Commonly, brass wires with a diameter of 0.010 inches are used.
Shape of Workpieces

Wire EDM can cut small and complex shapes. For handling multiple flat parts, stacking workpieces can enable efficient, unattended batch processing.

Materials for Wire EDM

This technology is extensively used in various industries. Pre-hardened mold steel is ideal for CNC Wire EDM, maintaining shape integrity without post-machining heat treatment. Titanium, known for its excellent conductivity, is well-suited for Wire EDM, generating minimal heat during the process and maintaining dimensional accuracy. Austenitic stainless steel, with its corrosion resistance and high thermal conductivity, ensures tool sharpness and prevents thermal damage. Tungsten and molybdenum, with high melting points, can withstand the high temperatures of EDM.

Applications of Wire EDM 

Wire EDM technology, combined with rotary positioning tables, finds broad applications across industries.

Component Processing

In conponent processing industries, Wire EDM can manufacture parts with precise tolerances and complex shapes. High-precision rotary positioning tables enhance the ability to machine spiral and gear-like parts, acting as work exchange tables for accurate multiple part processing.

Medical Devices

Wire EDM offers the precision needed for producing complex medical instruments, ensuring the efficacy and compatibility of medical devices by meeting stringent regulations.

Electronics

Wire EDM effectively produces microelectrodes used in microelectronics for circuits and sensors, where precise tolerances are critical for functionality.

Mold Tooling

Wire EDM can rapidly shape mold inserts, ensuring accurate reproduction of intended plastic parts. It’s also used to make stamping dies, extrusion molds, cutting punches, and more.

 Conclusion 

Wire EDM is a precise and efficient machining process that, when paired with rotary positioning tables, expands the range and scope of processing capabilities, making it ideal for various industries' complex shapes. Compared to many other manufacturing processes, it offers greater accuracy, efficiency, and cost-effectiveness, enhancing manufacturing competitiveness.

( Further Reading: Can It Be Used in a Cleanroom? https://www.herbao.com.tw/en/hot_495662.html )




Herbao Machinery continues to drive innovation, providing more professional and reliable solutions to our clients. For any technical questions, please feel free to contact us!

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