Page 3 - Spring 2024

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TECHTIPS • SPRING 2024

THE TRIALS AND TRIBULATIONS OF
EDM WIRE TESTING

AND COMPARISON

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BY ROGER KERNY ROGER KERNY ROGER KERN
B B
PRINCIP
PRINCIP
PRINCIPAL CONSULTANTAL CONSULTANTAL CONSULTANT
INTERNA
INTERNA
INTERNATIONAL TIONAL TIONAL
TECHNOL
TECHNOLOGY OGY OGY
TECHNOL
PROF
PROF
PROFESSIONALSESSIONALSESSIONALS
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I have witnessed remarkable improvements in the speed ve witnessed remarkable improvements in the speed
I ha
and accuracy of the Wire EDM process since I bought my acy of the Wire EDM process since I bought my
and accur
fi rst Wire EDM in 1975. Back then, one inch per hour was rst Wire EDM in 1975. Back then, one inch per hour was
fi
considered a decent cutting rate, but that speed has seen ate, but that speed has seen
considered a decent cutting r
a logarithmic rise as a result of breakthrough machine and ough machine and
a logarithmic rise as a result of breakthr
wire technologies. F
wire technologies. Fast forward to today, where there has ast forward to today, where there has
been a proliferation of different EDM wires, whose promot-oliferation of different EDM wires, whose promot-
been a pr
ers promise that their wire will lead to the promised land omise that their wire will lead to the promised land
ers pr
of speed and effi ciency. So, beleaguered by both ads and ciency. So, beleaguered by both ads and
of speed and effi
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pesky salespeople, what’s a shop owner/manager to do?’s a shop owner/manager to do?
pesky salespeople, what

DECIDE
DECIDE

Before proceeding to investigate these claims, the fi rst thing to determine is:
How important is increased speed to you, based upon your shop’s particular situation?

• Would your attention be better directed to increasing spark time on your machines?
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– The average percentage of spark time to available machine time for many shops is less than 50%.

Therefore, there are huge productivity gains to be had by addressing this issue rather than chasing new wire

cutting speeds.
– A comparative testing regimen comes at a cost: distraction from production.

How much promised speed increase is worthy of your attention?

How reliable are these claims and the source of them?
• Are these claims based upon the same type of work, material, machines and cutting conditions common
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to your shop?

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