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When we talk about wire EDM, the main attention is still on power supplies, wire quality, or machine rigidity. But there’s one system that can quietly decide whether you end up with a smooth surface or a part full of pits: the cutting fluid system.

Here’s what makes it worth reading through:

1. The type of fluid you use can directly affect discharge stability.

2. Filtration keeps debris from triggering secondary sparks.

3. Flushing design determines how quickly molten particles are cleared.

4. Pressure and flow balance is the difference between wire vibration and rough surfaces.

5. The fluid’s thermal and electrical roles reduce micro-cracks and stabilize the gap.

In the end, it defines surface integrity: roughness, recast layer, cracks, etc.

Or watch through: https://youtu.be/TWSIw1fMZxs?si=X9LpH-RLJtprUZdP

Breaking It Down

1. Cutting Fluid

Medium-speed WEDM relies on water-based fluid. Genuine cutting fluid should be skin-friendly, odorless, and certified. Despite that, we don’t recommend touching it without protection.

2. Filtration

Every spark leaves behind tiny debris. If it isn’t removed, it causes unwanted secondary discharges that roughen the surface. That’s why multi-stage filters and steady circulation are critical.

3. Flushing

Nozzle flushing is a reliable design. It clears molten particles before they can stick to the part. If flushing is weak or misaligned, you’ll see pits and more mess on the machine.

4. Pressure and Flow

Too strong? The wire vibrates, accuracy drops. Too weak? Debris stays in the gap and sparks lose stability. Get the balance right, and you get smooth surfaces with fewer defects.

5. Thermal and Electrical Roles

During cutting, fluid absorbs heat, reducing recast layer thickness and lowering the risk of micro-cracks. Its conductivity also controls the spark gap and helps define surface roughness.

Summary

Surface Integrity

All of this comes together in what we call surface integrity. Good fluid management means a smoother surface, fewer cracks, and stronger parts in the long run.

The cutting fluid system is not worth overlook. It’s coolant, cleaner, and spark stabilizer all in one. If you want better quality and fewer headaches, treat it as part of your regular machine management, not just a water tank in the corner.