Wire EDM Cut Estimator
UniversalEstimate cutting time, kerf width, recast-layer depth, and achievable surface finish for separating AM parts from build plates and cutting precision features in hardened AM metal. Wire EDM is the preferred separation method for LPBF — non-contact spark erosion avoids the vibration that bandsaw cutting imposes on thin walls and lattices.
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Formula
t_total = ( L × H / rate_mat ) × ( 1 + ( passes − 1 ) × 0.5 )
kerf = d_wire + 2 × spark_gap- t_total
- Total estimated cut time[min]
- L
- Cut path length[mm]
- H
- Workpiece height (section thickness)[mm]
- rate_mat
- Material-specific cutting area rate[mm²/min]
- passes
- Number of passes (1 = separation, 2–4 = finish)[—]
- recast
- Recast layer depth (lookup by passes)[µm]
Cutting area rates from published machine data (Sodick, GF AgieCharmilles). Low-machinability alloy corrections per Klocke et al., CIRP Annals (2014). Recast depth by pass count: 1 pass = 15 µm · 2 passes = 8 µm · 3 passes = 5 µm · 4 passes = 3 µm.
Recast layer
Recast layer must be removed by electropolishing or abrasive finishing before fatigue testing. The recast zone contains tensile residual stress and micro-cracks that dramatically reduce fatigue life.
Low thermal conductivity concentrates heat, producing a thicker recast layer than stainless at the same rate. Use skim passes to reduce it below 5 µm before electropolishing.
Sources
- [1]Klocke, F. et al. (2014) — Wire-EDM fatigue behaviour of titanium aluminide — CIRP Annals 63(1):233-236
- [2]VDI 3402 — EDM surface-finish reference
- [3]Sodick / GF AgieCharmilles — published wire EDM cutting-rate data — Cutting-area rate baselines (manufacturer tier)