Filters play a key role in optimizing your wire EDM. They filter out solid particulate, insulate the workpiece from the cutting electrode and flush away debris from the erosion gap. Choosing the right micron rating for your filters is critical for high quality surface finish and lower maintenance costs. Standardized measurements now make it possible to compare filter performance in a comparable way.
High Efficiency
Filtering is an essential process in the EDM machining operation. Impurities in the dielectric fluid lead to poor surface finishes and stress the mechanical parts of the wire EDM machine. These include the solenoids, valves, switches and roller bearings. This leads to high maintenance costs. Superior filtration qualities of the CFE range reduce the amount of dirt in the dielectric fluid which improves the cleanliness of the machine and helps to reduce these costs.
A good choice of micron rating is critical to ensure that the smallest particles are removed from the workpiece. Different materials machined with the wire EDM produce different sized particles. It is important to choose the right micron rating for each application to achieve maximum performance and optimum filter life. MANN+HUMMEL is working with the RWTH Aachen University to create a standardized test for edm filter that enables them to be classified according to their separation efficiency and service life. This will provide a way to easily compare the performance of different filters.
Long Life
A good wire EDM filter should be able to provide 400 hours or more of use. This is fully dependent on the material. TAGUTI’s strict material selection system ensures that the filters will have a long life cycle. Filter lifespan is critical because poor filtration can negatively impact long term maintenance costs for the machine. Solenoids, sight glasses and valves can be damaged by particulate build-up and are costly to replace or repair.
Additionally, poor filtration will cause the resin in your dielectric fluid to act as a filter and shorten its life span, again increasing unnecessary accrued costs. By using a high quality EDM filter that has a 5 micron rating or lower and maintaining proper lubrication, your machines will run for longer with less downtime.
Low Maintenance
Using the best quality filters will ensure that your machine cuts better than it should. A good filtration system will help you avoid costly repairs in the future. This is because poor filtration creates problems such as slowing cutting speed as the dielectric fluid becomes muddied, overheating and blocking of the internal components. This is especially true of the solenoids which power the EDM pump and circulate the dielectric fluid. If this happens, it could lead to costly replacements of the delicate parts. In addition, the contaminant-laden fluid can reduce resin life span and this is expensive to replace as well.
Keeping your wire, sinker and die-sinker EDM machines clean will save you a lot of money in the long run. Using an OEM-quality filter from a trusted supplier will provide you with many hours of service and the lowest possible maintenance costs. Moreover, it will protect your investment in the machine and give you peace of mind.
Reduced Downtime
Using the best OEM Quality EDM Filters reduces the need for filter replacements and backwashes. Unlike paper cartridges that require downtime for changing, filter systems with in-tank style and quick-connect fitting type filters can be backwashed without shutting down the wire EDM machine. Superior filtration qualities also result in less “dirty” dielectric fluid which reduces stress on the electrical and mechanical components in your EDM machine. This can extend the life of the solenoids, valves, switches and roller bearings while providing higher productivity and reducing maintenance costs.
Most knowledgeable EDM users agree that clean water is essential for quality cutting. Traditionally, they have considered a filter with a five- or 10-micron rating sufficient to meet their filtration requirements. However, many applications could benefit from a finer rating that would allow for longer resin life and improved part quality.
Final Word
Filter life varies based on the work being performed. Understanding how your shop’s operations impact filtration allows you to make considerations that optimize cutting and machinery performance. Poor filtration can cause expensive long term maintenance issues for your machine. Examples include damage to solenoids, sight glasses and plumbing components.
