1) Automatic Wire Threading System: The automatic wire threading (AWT) system performs the threading of the wire via a water jet column. It is the single most important automated feature on a wire EDM machine.

Utilization of an AWT system will extend the unattended operation of the machine. AWT units typically require cleaning and alignment checks of mechanical components and sensors to ensure reliable operation.

2) Power Contacts: These two contacts deliver the electrical cutting power to the wire. These contacts—both on the upper and lower machine heads—will erode over time, resulting in a significant decrease of machining speed. They require a simple indexing and cleaning, and eventual replacement.

3)Belts and Rollers: These items make up the wire transport system. They require either cleaning indexing, or replacement to prevent wire slippage or wire tension problems that can result in part inaccuracies.

4)Brake/Clutch Roller: This roller is the most critical item in the wire transport system. Its function is to create and control the proper tensioning of the wire. If wire tensions are not held to within certain parameters, workpiece inaccuracies, excessive wire breaks and excessive wire lines on the workpiece may result. This unit is typically maintained with the aid of an OEM (original equipment manufacturer) supplied procedure or calibration cycle.

5)Wire Guides (2): These guides—either diamond or sapphire—are located in both the upper and lower machine heads. They are used to align and locate the wire within the machine. The guides are the most important item within the machine because they deliver and transfer the machine tool accuracy into the workpiece. They require cleaning to prevent misfeeding, clogging, part inaccuracies and failure.

6)Wire Alignment: This procedure is typically required after wire guide cleaning with the aid of an OEM supplied jig or fixture, and is performed to calibrate and align the wire within the machine for verticality. If the wire is not properly aligned for verticality, machined results will contain tapers and positional part locations will be inaccurate.

7)Wire Collection Box: The wire is only used once within the machine, and will accumulate in a box or bin that will need to be emptied periodically. The spent or used wire should be routinely checked and emptied per manufacturer recommendations. The spent material can typically be recycled through an industrial materials scrap recycler.

8)Machine Seals: Many machine designs require cleaning of a door and tank seal to ensure seal integrity and longevity. Seals will need to be replaced once they become degraded beyond their service life and can no longer sufficiently prevent or control water leakage.

9)General Cleaning: With the intricate wire EDM process, debris is typically scattered evenly throughout the work tank.

Over time, this debris can accumulate and build up into a hard scale that is difficult to clean. Scheduling a monthly machine cleaning using a standard cleaner will prevent large buildups of debris. Less overall time will be required the more frequent the cleanings. Generally, the cleaner a machine is kept, the less likelihood there is for unsuspected problems to arise. This also may extend the life of some long interval consumable items.