The Benefit of The EDM Machining Process
The EDM Machining Process is one of the greatest innovations affecting the tooling and machining industry. This process made dramatic improvements to the industry in the aspect of accuracy, quality, productivity, and earning. Any electrically conductive material may be EDMed through wire EDM. If a customer with any project with such material such as material properties, Creatingway oversees it for you. There are 3 known EDM processes: wire EDM, small hole EDM, and RAM/sinker EDM.
What’s the RAK/sinker EDM machining process?
It is a similar machining technique to wire EDM with the use of spark erosion to derive desired cut-outs. The process involves the use of a conductive electrode pre-shaped and placed close to the workpiece. A dielectric fluid immerses both the workpiece and the electrode. The power setting alternates to achieve either a smooth finish or a rough finish. To achieve a smoother finish, we use a lower spark energy setting and vice versa. Sparks leave the electrode and erode the workpiece in the pre-shaped design. The electrode requires frequent replacement due to its exhaustion as the process continues.
The process is efficient in making square features, holes, and pockets inside hardened steel tools. Another common use is in molds for die casting and plastic injection.
How it works of the EDM machining process?
It resembles any other machining process. However, it uses a unique method of cutting electrically conductive metal. It begins with a new wire electrode fed into a workpiece through an upper diamond guide and a pulley system. The wire used commonly is brass why due to its high tensile strength and low vaporization temperature. The gauge of the wire ranges from 0.001 to 0.014” (0.025 to 0.357 mm). The used wire electrode exists the workpiece through a lower diamond guide and bottom roller where it eventually gets chopped up into small pieces. A pressurized, filtered and cooled dielectric fluid continuously fed into the upper and lower diamond guides by the assist of a pump.
The fluid ionizes, and sparks occur between the wire electrode and the workpiece. The sparks created precisely melt and vaporize the material. There is a gap between the brass wire and the workpiece to prevent the development of a short-circuit. A server mechanism that always maintains a gap between the workpiece and wire electrode even when cutting straight or at 45˚ taper. At a time, one spark created, but the process creates thousands of sparks per second. The precision capability cut is 125ths of the human hair.
When the sparking process is complete, the molten workpiece material collected, and pressurized dielectric fluid removes the eroded particles. A filter removes the EDM chips. Voltage and amperage control the spark between the wire electrode and workpiece.
What’s the machined capability?
At Creatingway, we recommend the use of wire EDM due to its wide range of finishing capabilities. It ranges from a rough cut to a mirror image finish on the workpiece. What determines the surface finish is the energy of sparks produced. We create minute sparks through skim cuts, where we repeat the process repeatedly, creating a mirror finish. Compared to other cutting techniques such as; laser cutting and use of an abrasive water jet; it does not equate to a cut of a wire EDM. The reason is the mushrooming out effect in the above processes, especially for large workpieces. It does not occur in wire EDM since spark erosion occurs throughout the entire length of the wire electrode. It is the reason for its accurate cutting.
When Should You EDM maching?
In answering this question, we look at two aspects in your project specification, i.e. geometrics produced, and materials machined.
When to EDM by material
- Hardness above RC 38: hardened steel, satellite tungsten, carbide
- Toughness: Inconel, Monel, Ha stelloy, Nitralloy, Waspaloy, Nimoric, Udimet
- Material with hazardous dust particles
- Frail/ fragile
Why to use EDM machined
- EDM vaporizes rather than cutting it, which other machining techniques use.
- EDM is non-contact; thus no adhesions form of workpiece to tool.
- There is continuous flushing away of particles through a filter, reducing the risk of fumes.
- No contact, no force
When to EDM by Geometry
- A small part (fit in a 0.2-inch cube)
- Accuracies difficult to hold, or maintain after heat treating
- Recessed cuts
- Very thin walls
Why to EDM by Geometry
- It involves no force or vibration thus easy to fixture.
- Can EDM conductive material of any hardness.
- Cutting tools not reaching cutting area or generate desired shapes.
- No contact, no force, no deformation thus maintaining thin dimensions.
What’s the advantage of wire EDM process?
Efficient Production Capabilities
Because of the precision and high-speed wire EDM machines, Creatingway uses it to manufacture many parts. It is more economical in production using wire EDM compared in cutting metal parts compared to other processes. The wire EDM machines have three different speed including fast speed, mid-speed, slow speed wire EDM machines.
in recent history, high-speed cutting wire EDM machines reduce costs for many manufactured costs. Usually, we use it to cutting many of shaped features since if we will use CNC cutting, the cost is too high.
Tight Tolerances and Excellent Finishes
At Creatingway, we uses the precision slow speed wire EDM machines, we can mahcined your parts accuracies up to +/- 0.001mm. and surface polishing Ra0.4 level.
Independent Axis Machining
Creatingway’s EDMing machines possess a 4-axis machining capability. It dramatically improves the range capability EDMed for various angular shapes.
If you are concerning the new projects budget limited or tight tolerance under high requirements, you can try the EDM process for the workpiece, Our EDM engineers with many years of experience will answer even the toughest of your questions.
Creatingway is concentrated on CNC machining manufacturing, prototype machining, low-volume manufacturing, metal fabrication and parts finishing services, provide you the best support and services. ask us one inquire now.
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