Increase Wire EDM Machine Efficiency with Magnetic Filters

Eclipse Magnetics’ filtration systems are proven to increase wire EDM machine, die-cast machining and EDM drilling efficiency by extending dielectric fluid life, reducing wire consumption and vastly reducing secondary sparking.

Wire Electrical Discharge Machining (EDM), also known as wire-cut EDM, is a very effective way to cut both hard and delicate materials within small tolerances.The high-quality finish and ability to cut intricate and complex shapes has led to the process becoming increasingly popular among manufacturers. However, there are accepted problems with the process that have previously been difficult to overcome. By introducing a cost-effective magnetic filter, manufacturers can reduce these key problems such as secondary sparking or re-sparking, wire breakage and machine downtime to improve the productivity of the machine.

What is Secondary Sparking and How Does Magnetic Filtration Help?

One of the biggest benefits of magnetic filtration in the EDM process is the reduction in secondary sparking. Secondary sparking occurs when particles flowing within the dielectric fluid attract the spark before the workpiece, wasting energy. Secondary sparking accounts for almost 30% of lost efficiency during the machining process.

Magnetic Filters  helps remove virtually all ferrous particles from the fluid - even those just microns in size - leading to a cleaner, more effective cut. With the removal of fine particles from the fluid, secondary sparking can, for the first time, be significantly reduced.

Effective filters for EDM Machines - Micromag

Other Advantages of Magnetic Filters in EDM Process

Without fine-particle filtration, materials below 10-20 microns flow freely within the fluid. If left to circulate, the particles can cause secondary sparking , wire breakage and in increased machine times.

Installing a magnetic EDM filter is proven to help with:

  • Increased fluid life
  • Reduced secondary sparking
  • Reduced wire consumption
  • Improved performance
  • Reduced downtime
  • Significant cost savings

With many manufacturers expecting payback on the EDM machine within 2 years, it can be a race against time to make the machines profitable.  Fitting a magnetic filter on an EDM machine offers an affordable option to speed up the EDM process and profit earlier from a better performing machine.

Micromag – The Ideal Filtration Solution for Wire EDM Machines

Our compact, high-performance Micromag magnetic filter offers the ideal solution for typical problems that arise during the EDM process.

Its high-intensity magnetic core and optimised fluid-flow orientation work effectively to remove virtually all ferrous particles from the dielectric fluid when used in conjunction with media filters. Its high collection capacity reduces machine downtime and cleaning can be done in seconds.

The low-cost Micromag is perfectly suited to offer a rapid return on investment, often within just weeks of installation.

Read about one of our successful EDM filter applications

Discover how our client ADM Precision Tools generates more than £200k in efficiencies from a £1,500 investment in Micromag EDM filter. 

"We were delighted with the service provided by Eclipse Magnetics; from the initial site survey through to delivery."

Adrian Seeley, Production Supervisor at AB MAURI UK & Ireland

"I cannot begin to tell you how much it has helped our operation, the magnetic filtration unit has been a real problem solver it has surpassed all our expectations. Its cured a 30 year plague!"

Maintenance Manager at EXL Tube (Steel Ventures)

"This technology is economical, reliable and efficient. I believe that magnetic filtration technology is the future."

John Smith, MMTCI

"Magnetic filtration has dramatically cleaned up our fluids and improved the surface finish we can offer. It extracts around 50Kg per day of ferrous waste."

Facilities Manager, Milacron Machines (Sub-Contract Machining)

"We chose Eclipse Magnetics to supply our housed grid because they are a respected and well-established brand. They offered us a very competitive price, and the process of ordering and installation was straightforward and reliable."

Pat Richards, Chief Engineer at Simpsons Malt

“We are delighted with the Automag installation; it’s solved all the problems we were having previously with downtime and maintenance costs. The filter means that we are able to use recycled water, which is saving us £1000 per week!”

Kenneth McRae, Principle Engineer at Vallourec

"Here at Qualflow, we base our business on a philosophy of make the product simple to use, reliable and cost-effective. Eclipse Magnetics’ neodymium magnets offer the strongest magnetic performance, and are nickel plated, making them a cost effective.."

Justin Lawler Ph.D. MBA, Chief Technology Officer at Qualflow Systems Ltd

"The Ultralift Plus magnetic lifter from Eclipse Magnetics is the perfect solution for the pick-up and transportation of the ultrasonic calibration blocks in our facility"

John Crossley, NDT Technology Lead at the Nuclear AMRC

"The result is an aesthetically pleasing system, which is effective in trapping metal contaminants and is easy to clean..."

Ian Aunger at Roquette