Wire EDM and CNC Titanium Machining for Complex Contour Components

Background: Precision and Complexity in Titanium Components

Wire EDM is essential for producing titanium components with intricate contours, thin walls, and sharp internal corners. Conventional milling and turning alone often cannot achieve the precision required for aerospace, medical, and high-performance industrial applications.

In this case, the customer required complex titanium components with features that included narrow slots, internal cutouts, and sharp radii. Integration of wire EDM titanium with CNC titanium machining ensured high accuracy and repeatability.

Material Selection and Machinability Considerations

Titanium alloys were selected for their strength, corrosion resistance, and fatigue performance. Machining titanium presents challenges due to:

• Low thermal conductivity

• High strength and work hardening tendency

• Difficulty in achieving sharp internal corners with conventional cutting

Wire EDM titanium mitigated these challenges by enabling cold cutting with minimal distortion.

CNC Titanium Machining of External Features

External surfaces, mounting points, and datum features were machined using CNC titanium machining prior to wire EDM operations. Operations included:

• Titanium milling for complex external geometries

• Titanium turning for cylindrical features

• Drilling and hole preparation for assembly

This ensured accurate reference surfaces for precise wire EDM alignment.

Wire EDM Titanium for Complex Internal Features

Wire EDM titanium was used for:

• Precision internal cutouts

• Narrow slots and thin walls

• Complex contour profiles

Optimized EDM parameters, including wire tension, pulse energy, and feed rate, ensured high dimensional accuracy and surface integrity. Multiple passes reduced recast layers and enhanced edge quality.

Integration and Hybrid Machining Workflow

The hybrid workflow combined CNC titanium machining and wire EDM titanium:

• CNC machining produced external features and datum references

• Wire EDM titanium created internal contours and precision cutouts

• Post-EDM finishing with milling or turning ensured flatness and surface quality

This approach minimized distortion and allowed consistent production of complex titanium CNC parts.

Tolerance Control and Surface Quality

Critical features were held within ±0.01 mm tolerance. Wire EDM ensured minimal kerf width, sharp edges, and smooth surfaces, suitable for aerospace and high-precision industrial assemblies. Post-machining inspections included:

• CMM verification

• Gauge measurement for functional features

• Surface roughness checks

Heat Treatment and Stress Management

Since wire EDM is a cold-cutting process, heat-affected zones were negligible. Selective stress relief and solution-aging treatments were applied only for components requiring additional structural stabilization.

OEM Support and Engineering Collaboration

The project followed an OEM model. Engineering teams collaborated to:

• Optimize wire EDM paths and cutting parameters

• Align CNC titanium machining sequences

• Plan post-EDM finishing and inspection

CAD/CAM software like SolidWorks, UG, and CATIA were used. Supported drawing formats included STEP, DWG, DXF, IGS, STL, and PDF. Prototype validation ensured full compliance before production.

Applications in Aerospace, Medical, and Industrial Sectors

Wire EDM titanium is widely applied for components requiring:

• Sharp internal corners and thin walls

• Complex contours for aerospace fixtures

• Precision parts in medical and industrial equipment

This capability expands design flexibility and ensures high-quality machined titanium parts.

Conclusion

This case demonstrates how wire EDM titanium, integrated with CNC titanium machining, produces complex contour components with high precision and minimal distortion. By controlling EDM parameters and combining finishing operations, manufacturers deliver reliable, functional, and dimensionally accurate titanium CNC parts.