SP wire is a hybrid electrode micro EDM wire consisting of a high-strength core and a highly-conductive outer shell, combining the advantages of tungsten-wire electrodes and brass-wire electrodes. This is achieved by applying our many years of experience in fine wire technology and metal plating skills. With its excellent tensile strength and ED characteristics, SP wire replaces conventional tungsten wire for precision EDM wire cutting.
ED Cutting Performance of SP Wire: SP wire is far superior to existing ED electrode wires such as tungsten wire in precision cutting performance, mechanical and ED properties, cost, etc. as shown below. These advantages maximize the performance of ED machines at less cost. Leading EDM manufacturers such as Mitsubishi, Sodic, AGIE Charmilles, Makino, Fanuc, etc., recommend SP wire as the best electrode wire.
Cutting speed: Improvement of =10% over tungsten wire, thanks to SP wire’s high electrical conductivity.
Surface roughness: Due to its excellent ED stability and high tensile strength, SP wire provides a fine surface roughness as good or better than that of brass wire.
Cutting Width (clearance): With its high tensile strength and stable ED characteristics, SP wire provides precise, fine ED cutting where the cutting width (clearance) is =20% narrower and the corner radius is smaller than that with tungsten wire. Thus, the same machining accuracy can be obtained with one size larger SP wire, along with a much faster cutting speed.
Abrasion Of Wire Guides: Since SP micro EDM wire is flexible and has a soft and smooth surface, abrasion of the wire guides (electrified pins, guide rollers, etc.) of EDM machines is far less than that with tungsten wire, reducing operating costs.
Automatic Wire Threading: SP micro EDM wire has excellent free cast and straightness, allowing a highest rate of automatic wire threading.
Longer Length: SP micro EDM wire provides a longer continuous length per reel: 5,000m/reel, 10,000m/reel and 20,000m/reel, while that of tungsten wire is 3,000 - 5,000m/reel. Thus, longer continuous operation and higher productivity can be achieved.
Surface Stability: Unlike tungsten wire, SP wire is invulnerable to surface oxidation. Thus yielding longer shelf life.
HOMO Phenomenon: The HOMO phenomenon, an unstable ED caused by the short-circuit ,that occurs when cutting a tungsten-containing work piece (e.g., tungsten carbide) with a tungsten wire, does not occur with SP wire.
Cost Performance: In addition to the excellent properties above, SP micro EDM wire is far less expensive than tungsten wire, providing an excellent cost performance.
Setting Cutting Conditions: To find the optimum cutting conditions for SP micro EDM wire, first set the cutting conditions for a brass wire electrode having a diameter equal to SP wire. Then gradually increase the wire tension until the SP wire breaks. The optimum tension is that just before breakage. You may also be able to obtain SP wire cutting condition data from EDM manufacturers.
