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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.)
  4th-Axis Rotary Module Middle & Base Plate ProcessMilling, Grinding, Measurement, and Assembly  Applications of 4th-Axis Modules in Precision Manufacturing In aerospace, mold, automotive, and medical industries, the 4th-axis CNC rotary table is an essential device for improving machining efficiency and multi-face processing capability. It enables cutting operations on different angles and surfaces in a single setup, reducing workpiece repositioning time and errors, while ensuring machining accuracy and productivity.  Design Functions of the Middle Plate and Base Plate The middle plate serves as the structural interface between the 4th-axis rotary platform and the tailstock. It must withstand the weight of the workpiece and machining loads, ensuring the accuracy of fixture and workpiece installation.The base plate acts as the mounting reference for both the 4th axis and the tailstock. In addition to providing stable support, it also absorbs vibration and reinforces the structure, reducing chatter and deflection during machining and improving overall rigidity and stability.   Raw Material Inspection and Milling Process  Before starting the process, various types of calipers and measuring tools are used to confirm that the raw material’s length, width, and height meet the design specifications.Prior to CNC milling, a 3D dial gauge is used to set the workpiece coordinate system, ensuring precise positioning. During machining, multiple cutting tools are applied in sequence according to the program to complete operations such as threaded holes and countersunk holes.Each tool operation is controlled by the CNC program, including feed rate, cutting depth, and tool change order, ensuring machining consistency and precision. Although the base plate primarily serves as a spacer, its flatness and hole position accuracy must also be strictly controlled to avoid interference or misalignment during assembly.  Grinding and Surface Accuracy Inspection After milling, the process proceeds to grinding, where a surface grinder equipped with a grinding wheel removes a small amount of material to eliminate tool marks and deformation errors, reducing the surface roughness to below the Ra standard value. Coolant is applied during grinding to control heat buildup, preventing thermal deformation from affecting accuracy.After grinding, multiple precision inspections are carried out:◆ Height gauge and probe – Check thickness and parallelism.◆ Outside and inside micrometers – Verify bore diameters and thickness accuracy.◆ MarSurf roughness tester – Measure Ra and Rz to ensure surface performance.◆ Digital microscope – Inspect grinding patterns and detect surface defects.◆ WENZEL CMM – Verify hole pitch, flatness, parallelism, and perpendicularity with micron-level accuracy.  4th-Axis Modular Assembly Process  Assembly begins with installing the L-shaped mounting base of the rotary platform. A dial indicator is used to check face runout, ensuring positioning accuracy. The tailstock is then installed, aligned with the center of the rotary platform, and secured to keep the workpiece tail end stable and free from vibration during machining.The 4th axis and tailstock are mounted onto spacer blocks or the base plate, followed by dual-axis alignment. A dial indicator measures the shaft height and position at both ends, with repeated adjustments until the coaxiality error meets the required standard.Finally, the middle plate, motor cover, and side panels are installed in sequence, the brand logo is fixed, and the final test run is performed.  Quality Commitment and Technical Expertise  Since its establishment in 2008, Herbao Machinery has specialized in the research, development, and manufacturing of high-precision CNC rotary indexing tables. With multiple patents and a complete process control system, every stage—from design, machining, and inspection to assembly—is strictly monitored to ensure long-term stable operation, meeting the high precision manufacturing standards demanded by various industries.For more practical applications and technical knowledge about 4-axis and 5-axis systems, visit our website, follow us on social media, or subscribe to our YouTube channel to receive the latest insights and hands-on sharing. ( (Related Reading: How to Maintain a 4th Axis? Knowledge Sharing Ep. 8-How to Maintain a CNC 4th-Axis Rotary Table? ) Herbao Machinery remains committed to advancing technology and delivering professional,reliable solutions for our customers. Please contact us for any technical inquiries！ https://www.herbao.com.tw/en/hot_520766.html Knowledge Sharing #9 – Machining & Assembly of 4th-Axis Rotary Module Middle and Base Plates | Precision Manufacturing 2025-08-06 2026-08-06
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_520766.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_520766.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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