Berkenhoff launches two new high-performance EDM wires

The wire manufacturer Berkenhoff, pioneer in spark erosion with coated wires, has expanded its topas plus EDM wire range. The topas plus H 2.0 and topas plus V ranges are designed for high cutting speeds, and can be used with high precision even on workpieces over 100 mm thick.

Electrical discharge machining (EDM) is a precision-cutting process for metallic conducting workpieces. In an EDM machine, the workpiece to be machined and the tool (an EDM wire) are connected by means of a pulse generator. Its voltage pulses produce sparks, which separate material from the workpiece. The cutting gap between the wire and the workpiece is continuously flushed with dielectric to remove the eroded material and to cool the thermally stressed wire. Modern EDM machines work with ever higher-powered pulse generators, enabling shorter machining times and higher productivity. To take full advantage of their high effectiveness, high-performance EDM wire is needed.

topas plus H 2.0 and topas plus V 

The high-performance EDM wires topas plus H 2.0 and topas plus V have a core of brass and a brass coating whose raised zinc content improves cutting performance and increases the wire’s thermal resilience. Because of their coating microstructure, these EDM wires are also known as gamma-phase wires. 

Unmanned production possible

The two wire types have high thermal resilience and a tensile strength of 800 MPa. Because of their high rigidity that results from this, they are very well suited for EDM machines that require a straightened EDM wire for threading. In case of wire breakage, automatic threading is guaranteed. This is important when the machines continue to operate at night unattended. 

Machining thick workpieces

The thermal resilience of the two wire types makes it possible to machine workpieces with large cutting thicknesses. Thicknesses up to 100 mm, and in special cases even up to 1,000 mm, can be machined with precision. This brings a significant increase in output compared to other wire types, especially under unfavorable flushing conditions.

Differences

The differences between the two wire types lie predominantly in the coating, and thus in their cutting performance. You can use topas plus H 2.0 to replace plain brass wire, and with the same settings it brings productivity increases of up to 25%. With adjusted settings, you can increase cutting performance by up to 35%. topas plus H 2.0 is suitable for applications with up to 5 cuts.
topas plus V can achieve cutting performance at least 10% greater than topas plus H 2.0. It can increase cutting performance by up to 45% compared to plain brass wire. topas plus V is ideally suited for applications with up to 4 cuts. 

Application

Berkenhoff’s top priority is increasing its customers’ productivity. topas plus H 2.0 and topas plus V high-performance EDM wires are intended for machining tools, molds, and machine elements, where productivity plays a major role. Typical parts include extrusion molds, like those for plastic-frame window components, and mold parts for large gear wheels.

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Berkenhoff GmbH (headquarters)

  • Kinzenbach plant
  • Berkenhoffstrasse 14
  • 35452 Heuchelheim
  • Germany

Berkenhoff GmbH

  • Merkenbach plant
  • Rehmühle 1
  • 35745 Herborn
  • Germany

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