Rotary Connecting Block for Automation: Wire EDM Deep Slot & Side Irregular Through-Hole with Multi-Face Perpendicularity

We manufactured a precision rotary connecting block from hardened mold steel for an industrial automation rotary actuator system. This component features a deep locating slot and complex irregular through-holes on the side face — geometries that would require multiple milling setups and custom form tools. Using slow wire EDM, we cut all features in a single setup, ensuring perfect perpendicularity between multiple faces and eliminating cumulative fixturing errors.

Project Overview

Key Technical Highlights

• Single-Setup Wire EDM: Deep slot and side irregular through-hole were cut in one fixturing setup using programmed wire path rotation, eliminating misalignment between features common with multi-operation milling.
• Multi-Face Perpendicularity: Achieved 0.008mm perpendicularity between the deep slot and base reference face, and 0.010mm between the side irregular hole and base — critical for smooth rotary motion in automation assemblies.
• Irregular Through-Hole Precision: Custom D-shaped and keyway profiles were cut directly without custom broaching tools or secondary EDM burning, holding ±0.005mm contour tolerance.
• Hardened Material Integrity: Wire EDM cut mold steel at 50–56 HRC with no heat-affected zone or micro-cracking, preserving wear resistance for high-cycle rotary applications.
• Deep Slot Straightness: Maintained 0.006mm straightness over full 38mm depth, ensuring consistent engagement with mating slide components.

Quality Verification

Every rotary connecting block underwent Hexagon CMM inspection for slot position, irregular hole contour, and all perpendicularity requirements. Deep slot straightness verified with precision pin gauge and air gauge. Surface finish measured with profilometer (Ra≤0.4μm). A 100% fit test was performed with mating rotary actuator components.

Industry Applications

This rotary connecting block is ideal for:
✓ Rotary actuator linkages
✓ Automated indexing tables
✓ Pick-and-place rotary arms
✓ Cam-driven automation systems

Why Partner With Us?

• Single-setup wire EDM for multi-face perpendicularity
• Direct cutting of irregular through-holes without custom tooling
• Deep slot + side feature integration in one operation
• 25+ years of automation component precision machining