How to Best Manage Your Wire Consumption for Wire EDM

Wire consumption is a critical factor for many wire EDM (Electrical Discharge Machining) users, especially in high-volume production or when running premium coated wires. The cost of wire can be a significant portion of the consumables expense, so claims of 10%–40% savings are understandably attractive—but they warrant closer scrutiny.

5 Key Considerations for Wire Consumption Claims:

1. WHERE ARE THE SAVINGS?

First Pass vs. Skim Passes: Some manufacturers optimize wire feed rates during the roughing pass, while others focus on skim passes where lower energy and faster feed rates are possible. Ask for specifics: Are the savings realized during roughing, finishing, or both?

Material Thickness: Many systems adjust wire speed based on workpiece thickness. Savings may only apply to certain thicknesses (e. g., under 100 mm), so clarify the thickness where the claimed savings occur and how often you are in that range.

Technology or Wire Type: Some savings depend on advanced power supply technology or are specific to certain wire coatings (e. g., zinc-coated, diffused wires). Ask if the savings are universal or require proprietary wires.

2. BASIS OF COMPARISON

Old vs. New Technology: Manufacturers sometimes compare their latest models to their older ones, not to competitors. Request head-to-head data against other brands under identical conditions.

Test Conditions: Are the savings shown in real-world production or in controlled lab tests? Request sample parts, cutting parameters, and independent verification if possible.

3. IMPACT ON YOUR ACCURACY AND FINISH

Profile Accuracy: Slower wire speeds or reduced tension can affect straightness, corner accuracy, and surface finish. Ask for data on part accuracy and surface roughness at the claimed wire-saving settings.

Consistency: Will reduced wire consumption impact cut consistency over time or with different wire batches?

4. CONTROL AND ADJUSTABILITY

User Control: The ability to manually adjust wire feed rates based on job requirements, wire type, or desired finish is valuable. Some controls allow real-time adjustment; others are locked to preset technologies.

Wire Coating or Technology: If you use specialized wires, confirm whether the control system can optimize feed rates for those specific types.

5. PROOF AND TRANSPARENCY

Demand Proof: Ask for detailed test reports, not just marketing claims. Request to run sample parts on your own jobs or see customer references.

Ask for Data: Look for documentation on:

• Wire consumption per hour or per part
• Part accuracy (tolerances held)
• Surface finish (Ra values)
• Cutting speeds and power settings

Would you like the ability to control and adjust wire consumption automatically without affecting the quality of the finished part?