Abstract: An electrode wire with multi-coated layers for electrical discharge machining (EDM) is capable of fast and precisely machining a work piece for a desired shape without changing the electrode wire, and a method of manufacturing the electrode wire is obtained by performing the steps of manufacturing a core wire, coating the core wire with zinc, drying the coated core wire, diffusion-heat treating of the coated core wire, drawing a product from the coated core wire, and stabilization treating of the coated core wire in order.

Abstract: Disclosed is a method of manufacturing a zinc-coated electrode wire for electro discharge machining using a hot dip galvanizing process. The method includes firstly surface-forming a wire (1) in such a way that its terminal end is tapered while the wire is drawn through a first die at step 10, pre-coating zinc around the firstly processed wire in a molten zinc bath (2) at step 20, main-coating the pre-coated wire with zinc (3) using a sizing die before zinc pre-coated on the wire is hardened at step 30, secondly surface-forming the main-coated wire in such a way that zinc coated around the wire has a uniform thickness using a second die having a smaller diameter than the wire at step 40, heat-treating the secondly surface-processed wire at step 50, and drawing the heat-treated wire using a third die (5) made of natural diamond at step 60.