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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.)
  Pneumatics vs. Hydraulics: Which Is Better？A Deep Dive into Power Choices for Automation Equipment In the design and application of automation equipment, pneumatic and hydraulic systems are the two most commonly used drive mechanisms. Whether it’s positioning, clamping, or pushing on industrial production lines, or handling heavy-load operations in large machinery, choosing the right actuator is crucial to ensuring equipment efficiency and stability.This article explores the differences between pneumatic and hydraulic systems across four key aspects: working principles, performance characteristics, application scenarios, and cost-effectiveness, helping you identify the most suitable solution for your needs. Features and Advantages of Pneumatic Systems Pneumatic systems, typically powered by compressed air, generate linear thrust by controlling the pressure differential between the two chambers of a pneumatic cylinder. As air is a compressible medium, pneumatic systems offer fast response times and excellent shock absorption, helping reduce vibration and impact during high-speed operations.Key advantages include:Simple structure and easy maintenance: Pneumatic systems have fewer components, and their modular design simplifies servicing and upkeep.Quick response: Fast airflow enables rapid actuation, making pneumatics ideal for short-stroke, high-frequency operations.Low cost: Compared to hydraulic systems, pneumatic equipment typically requires lower initial investment and maintenance expenses.Clean and eco-friendly: Using air as the working medium avoids the risk of fluid leaks or contamination, making it environmentally safe.Suitable for light-load operations: Especially effective for tasks such as packaging, assembly, and sorting in compact automation setups. Features and Advantages of Hydraulic Systems  Hydraulic systems (hydraulic cylinders) use hydraulic oil as the working medium, delivering stable pressure and flow through a hydraulic power unit. Direction and speed of the fluid are precisely controlled using proportional valves or solenoid valves, which drive the piston’s movement. Based on Pascal’s Law, since fluids are nearly incompressible, hydraulic cylinders offer exceptional rigidity and stable force output. Key advantages include:High force and stability: Ideal for long-duration, high-load, and high-pressure applications.High positioning accuracy: Hydraulic pressure is consistently transmitted, allowing for more precise control than pneumatic systems.Excellent holding capability: Hydraulic cylinders can maintain their position for extended periods, even when the machine is stopped.Seamless CNC integration: Widely used in industries such as heavy cutting, mold forming, and metalworking due to their robust performance.  Practical Application Recommendations If your automation line prioritizes high-speed cycles, lightweight operations, and cost control, pneumatic cylinders are the ideal choice. Especially for short-cycle tasks such as assembly, handling, and sorting, pneumatic systems can deliver maximum efficiency with minimal resources. However, when the task involves heavy loads, precision machining, or sustained force over long periods, the high output and rigidity of hydraulic cylinders become indispensable advantages. In applications like die casting, steel forming, and large workpiece processing, the stability of hydraulic systems is directly tied to product accuracy and production efficiency.  Hybrid Applications of Pneumatics and Hydraulics  As production lines become more complex, more equipment is adopting hybrid systems tailored to different process stages: pneumatic cylinders are used in the early stages for fast positioning and gripping, while hydraulic cylinders are implemented in the mid or final stages for stable pressure-driven operations. This setup not only balances efficiency and precision but also effectively controls overall costs.  Conclusion  By understanding the core differences and application strategies of pneumatic and hydraulic cylinders, you’ll be able to choose the most suitable solution based on your operational needs.If you have any questions regarding automation equipment, pneumatic systems, or hydraulic planning, feel free to contact Herbao Machinery. We are here to help you build the optimal production solution！  FAQs: Pneumatic vs. Hydraulic Systems  Q1: Which system is more energy-efficient?A: Pneumatic cylinders are generally more energy-efficient because they consume energy only during operation, and compressed air can be supplied centrally. In contrast, hydraulic systems require a continuously running power unit, leading to higher energy consumption.Q2: Which system is better for high-precision control?A: Hydraulic cylinders are better suited for high-precision control due to the incompressibility of liquid, offering stable output and accurate positioning — ideal for heavy-duty and precision-demanding tasks.Q3: Do pneumatic cylinders have a shorter lifespan than hydraulic ones?A: Not necessarily. Pneumatic cylinders are simpler in design and easier to maintain. With clean air and proper upkeep, they can operate reliably over long periods. Hydraulic cylinders, however, require regular monitoring of seals and fluid quality.Q4: Can pneumatic cylinders replace hydraulic cylinders?A: In some applications, yes — especially for lighter loads and tasks with lower force requirements. However, for long-duration, high-force, and precision positioning, hydraulic cylinders remain essential.Q5: Can both systems be used in the same machine or production line?A: Absolutely. It’s common to use pneumatic cylinders for lightweight, rapid operations and hydraulic cylinders for heavy-duty or critical positioning tasks, achieving the best balance between performance and cost.Q6: Which system is easier to maintain?A: Pneumatic systems are generally easier to maintain, with straightforward component replacements and lower risk of failure. Hydraulic systems are more complex, requiring clean fluid circuits, stable pressure, and attention to seal integrity. ( Further Reading: Is it difficult to switch from manual to automatic operation? Check out a real-world case in Technical Application Vol. 5 — [Equipment Upgrade Case] Automation Retrofit｜Air Cylinder + Control Module for Time & Effort Savings ) Herbao Machinery is committed to continuous innovation, providing professional and reliable solutions for your automation needs.Feel free to contact us with any technical inquiries！ https://www.herbao.com.tw/en/hot_522917.html Knowledge Sharing Issue #10 Pneumatics vs. Hydraulics: Which Is Better? A Deep Dive into Power Choices for Automation Equipment 2025-09-17 2026-09-17
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_522917.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_522917.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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