Wire- and die-sinking electro-erosionWe will check feasibility and get back to you shortly.
Erosion & Electrical discharge machining (EDM) – Wire erosion and Die-sinking erosion for maximum precision
When geometries are complex and very small , materials become hard or tolerances move into the µ range is erosion (also spark erosion or. EDM – Electrical Discharge Machining) is often the most economical and safest manufacturing process. Sharp-edged internal contours are not an exclusion criterion for us a35> us. Bonsack precision engineering supports you with wire erosion and sinker EDM as contract manufacturing – for precise contours, fine details and reproducible quality.
Whether tool components, active parts, functional components or spare parts: We manufacture eroded precision parts that function in series production – and impress in every detail.
What does erode (EDM) mean?
In spark erosion, material is not removed by cutting, but by controlled electrical discharges between the electrode and the workpiece. Sparks are generated in a dielectric (insulating fluid), which remove tiny particles of material from the surface. This allows contours to be created that are difficult or impossible to produce reliably using milling or turning, especially in the case of hardened steels, carbide or alloys that are difficult to machine.
Important for practical application: Erosion is not a “replacement” for CNC machining, but rather a high-precision supplement – whenever internal contours, intricate details, sharp corners or very tight tolerances are required.
Wire erosion – precise cutting contours, fine radii, reliable repeat accuracy
Wire electrical discharge machining (Wire EDM)
is ideal for precise contour cut-outs and cutting geometries. A thin wire serves as an electrode and cuts the desired contour along a programmed path. The process is particularly effective when:
- complex 2D contours or precise cutting profiles are required,
- Workpieces are already hardened (e.g. tool steels),
- close fits, defined edges and constant repeatability are required are,
- low cutting forces are important for low distortion machining).
Typical
applications
are active parts in toolmaking (e.g. cutting inserts, die/punch contours), precise guide – and contour elements as well as spare parts for existing tools. Through multi-cut strategies, it is possible to improve surfaces and dimensional accuracy can be specifically improved – depending on material, component thickness and contour complexity.
Die-sinking EDM –
3D contours,
filigree details and internal geometries
die-sinking EDM
(Sinker EDM, Ram EDM) works with a shaping electrode (e.g. graphite or copper) that “sinks” the desired negative geometry into the workpiece. This process is the first choice when:
- 3D cavities, pockets or mould contours are required,
- Internal geometries with sharp corners/small radii are required to be,
- complex forms in mould making and tool making are to be created in,
- hardened materials must be reworked.
The strengths
Die sinking EDM really shows its strengths when it comes to tool and mould components, like contour inserts, functional surfaces, structured cavities, or geometries that would be really risky to make mechanically (tool breakage, warping, burr formation).
Erosion vs. milling:
When is EDM the better choice?
Combination
In many projects the best solution is a combination of CNC machining, grinding and EDM. Eroding is typically used when one of the following applies: when one of the following requirements is in the foreground:
- Hardness & Material: Hardened tool steels, carbide or difficult-to-machine materials.
- Geometry: sharp inner corners, very small radii, delicate contours, deep and slim geometries.
- Process reliability: low forces, thereby less warping – especially in thin-walled areas.
- Wiederholgenauigkeit: reproduzierbare Ergebnisse für Serien- oder Ersatzteilfertigung.
economic efficiency
Milling is often faster for open geometries, large volumes or when the contour is mechanically easily accessible is. EDM becomes then economical, if milling strategies become extremely complex (special tools, long running times, high wear) or if certain contours are difficult to access. high wear) or if certain contours simply cannot be milled are a32>.
Materials, tolerances
and surfaces – what is possible with spark erosion ?
Erosion is particularly suitable for materials that are in machining are demanding are. Typical materials in the EDM contract manufacturing are:
- Tool steels (hardened and unhardened), hot-work steels and cold-work steels
- powder metallurgical steels
- carbide
- Stainless steels and high-alloy steels
- Other electrically conductive materials and special alloys
Tolerances and surfaces depend heavily on geometry, material, component thickness and the selected cutting/erosion sequence. In practice, the are – depending on the boundary conditions – very tight dimensional tolerances and fine surfaces can be achieved. For many applications in toolmaking are defined fits, repeatable contours and clean cut surfaces are crucial – exactly for this is EDM designed.
Important: We coordinate requirements such as fit, surface quality and function with you (drawing, tolerance concept, application) in order to determine the most economical process route.
Typical areas of application:
toolmaking, active parts, precision parts and spare parts
EDM components are used wherever precision and service life are important. Frequent areas of application for our customers:
- Toolmaking/mould making: inserts, contour elements, cavities, slide/guide components
- Punching- and forming technology: Cutting contours, die/punch geometries, progressive die- and fine blanking parts
- Near-series production: functionally critical precision parts with demanding internal contours
- Maintenance & spare parts: Reproduction of eroded components for existing tools
When it comes to spare parts in the tooling sector, the ability to precisely rework hardened components or reproduce them according to drawings is a real advantage – ensuring short downtimes and quick recommissioning.
Your project at Bonsack – From drawing to tested component
In order for EDM to function economically and reliably, it is essential to have a clear process plan in place. Typical procedure:
- Enquiry & Data check: Drawing, 3D data (if available), Tolerances, material, Application.
- Feasibility & process coordination: selection of wire EDM/die-sinking EDM, cutting strategy, electrode concept (if necessary), surface target.
- Manufacturing: Precise EDM machining, if required combined process chains with CNC/grinding.
- Quality assurance: measurable testing, documentation in accordance with agreement.
- Delivery: on time, protected packaged, on request with measurement report.
The result is functional, ready-to-assemble or ready-to-use components that can be seamlessly integrated into your tooling or production processes.
Quality assurance & documentation –
crucial for series production readiness
Particularly in the case of active parts and functionally critical tool components, it is not only dimensional accuracy that counts, but also process reliability and verifiability. Bonsack works with clear testing processes and documented quality. Depending on requirements, we provide support in areas including:
- measurable testing relevant characteristics (e.g. fit dimensions, contour accuracy, functional surfaces)
- measurement reports according to agreement
- Traceability for recurring production and spare parts
- tailored packaging for sensitive surfaces and contours
This means you receive not only a component, but also a reproducible result – in line with your quality and supply chain requirements.
We prepare a robust offer with a realistic ramp-up.
FAQ – Frequently asked questions about eroding, wire eroding and die-sinking eroding
What is the difference between wire EDM and die-sinking EDM?
During wire erosion cuts a wire as an a8> electrode cuts the contour along a path – ideal for precise cutting profiles and openings. During sinker EDM a a24> shaping electrode is used to create 3D cavities and internal geometries to produce.
When is erosion more useful than milling?
Eroding is particularly useful for hardened materials, with very tight tolerances or if geometries are difficult to mill in terms of milling technology are difficult (e.g. sharp internal corners, small radii, deep, slim contours). Often, a combination of milling/grinding and EDM is the most economical solution. a30> milling/grinding and EDM is the most economical solution.
Which materials can be spark eroded?
In principle, electrically conductive materials can be eroded. Typical examples are tool steels (including hardened), carbide, high-alloy steels and other special alloys.
How precise is electrical discharge machining (EDM)?
EDM eignet sich für sehr präzise Konturen; die erreichbare Genauigkeit hängt u. a. von Material, Geometrie, Bauteildicke und Prozessstrategie ab. Für viele Werkzeug- und Aktivteilanwendungen sind sehr enge Toleranzen und reproduzierbare Passungen realisierbar.
What advantages does EDM offer for tool components and active parts?
EDM enables accurate contouring geometries with low mechanical stress on the a9> workpiece, which reduces distortion . In addition it is possible to produce contours and internal geometries that which mechanically would only be possible with great effort or risk.
Can Bonsack manufacture complete tools?
Bonsack manufactures high-precision individual components for tools (e.g. inserts, active parts, spare parts), but not complete tools as overall assemblies for customers.
How quickly are typical delivery times?
Delivery times depend on geometry, material availability, testing requirements and capacity utilisation. Many projects can be implemented quickly – it is best to send us your drawings and requirements so that we can suggest the most cost-effective route and a reliable delivery date.