Calculate precise Electrical Discharge Machining costs for wire EDM, sinker EDM, and small hole drilling. Estimate electrode costs, machine time, and precision machining expenses.
EDM Process Type
Electrode Specifications
Typical: 1-5% for graphite, 10-30% for copper
Workpiece Material & Specifications
Affects cutting speed and electrode wear
Raw material + previous operations
Precision & Surface Requirements
Precision Grade: ±0.010mm
Rough (3.2μm)
Standard (1.6μm)
Fine (0.8μm)
Very Fine (0.4μm)
Lower Ra = Smoother surface = More time
Estimated Electrode Wear Ratio
Estimated Wear Ratio: 1.5% (Graphite)
Machine & Operational Costs
Typical: $75-150/hour
EDM Machining Cost Analysis
Cost Per Part
$287.50
Total Machining Time
4.2 hours
Material Removal Rate
45 mm³/min
Detailed Cost Breakdown
Machine Time Cost
$218.50
Cutting time + setup
Electrode/Wire Cost
$35.75
Consumables + wear
Labor Cost
$67.50
Setup and monitoring
Profit Margin
$112.75
Business profit
Process Analysis
Actual Cutting Time
2.7 hours
Wire/electrode engagement time
Electrode Wear
2.1%
Material lost from electrode
Surface Quality
0.8 μm Ra
Achieved surface finish
Time Distribution
Method Comparison
EDM Process Optimization Tips
Based on your parameters, consider using coated electrodes to reduce wear by 15-25%. Multi-stage roughing can improve overall efficiency by 30%.
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Frequently Asked Quentions
1. How much does EDM machining cost per hour?
EDM machining costs range from $75-150 per hour depending on process and machine capability. Wire EDM typically costs $75-120/hour, sinker EDM $90-150/hour, and small hole EDM $70-100/hour. Premium machines with advanced features and automation command higher rates.
2. What is the main cost difference between wire EDM and sinker EDM?
Wire EDM costs are dominated by machine time and wire consumption ($40-120/kg), while sinker EDM costs include significant electrode fabrication expenses ($0.25-5.00/cm³) plus higher machine rates. Wire EDM is generally more cost-effective for 2D profiles, while sinker EDM excels for 3D cavities.
3. How long does EDM machining typically take?
EDM is relatively slow compared to conventional machining. Typical material removal rates: 30-80 mm³/min for sinker EDM, 50-150 mm/min cutting speed for wire EDM. A complex mold component might take 4-12 hours, while simple shapes could be 1-3 hours. Multiple passes for fine finishes significantly increase time.
4. What materials can be machined with EDM?
EDM machines any electrically conductive material regardless of hardness. Common materials include: tool steels (hardened and soft), stainless steels, carbides, titanium, inconel, aluminum, and copper. Material hardness affects cutting speed but not tool wear like conventional machining.
5. What is the typical electrode wear in EDM?
Electrode wear varies by material: graphite 1-5%, copper 15-30%, copper tungsten 5-15%. Wear increases with finer finishes and harder workpiece materials. Modern power supplies and adaptive control can reduce wear by 20-40% through optimized parameters.
6. How accurate is EDM machining?
Standard EDM accuracy: ±0.025mm, Precision EDM: ±0.010mm, High-precision EDM: ±0.005mm, Ultra-precision EDM: ±0.002mm. Accuracy costs increase significantly with tighter tolerances - ±0.005mm typically costs 60-100% more than ±0.025mm.
7. What surface finishes can EDM achieve?
Standard EDM finishes: 1.6-3.2μm Ra, Fine finishes: 0.8-1.6μm Ra, Very fine finishes: 0.4-0.8μm Ra, Mirror finishes: <0.4μm Ra (with special techniques). Each step improvement in surface finish typically increases machining time by 50-100%.
8. Can EDM machine non-conductive materials?
No, EDM requires electrically conductive materials. However, special techniques can machine conductive coatings on non-conductive substrates, or create conductive surfaces for initial EDM penetration. For non-conductives, consider laser, ultrasonic, or conventional machining.
9. What is the minimum order quantity for EDM work?
Most EDM shops have minimum charges of $150-300 for prototypes and $300-600 for production work. Complex mold work often has $500-1,000 minimums. Small hole EDM might accept smaller orders starting at $100-250.
10. How does EDM cost compare to CNC milling for hard materials?
For materials under 45 HRC, CNC milling is typically 60-80% cheaper than EDM. Above 45 HRC, EDM becomes competitive, and above 55 HRC, EDM is often more cost-effective due to no tool wear and ability to machine complex geometries in hardened state.
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