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You also have the option to opt-out of these cookies. This takes out distortion brought about by hardening and stress-relieving. Unlike conventional processes, an EDM surface has a very random texture.
This entails taking multiple skimming passes, for which the wire EDM cutting rate needs to be very low. On the right job — complex 2D geometry, hard material — EDM offers cost savings over conventional processes.
For example:. EDM requires an electrically conductive workpiece. It will not work on wood, plastics or composites. Material removal rates MMR are usually lower than for conventional processes. The last type of electrical discharge machining is called hole drilling EDM. As the name suggests, this process is used for drilling holes. Compared with traditional drilling methods, EDM is able to machine extremely small and deep holes. Additionally, EDM drilled holes don't need any deburring.
The electrodes in this process are tubular and the dielectric fluid is fed through the electrode itself. In general, every conductive material can be machined with electrical discharge machining. Common materials include metals or metal alloys such as hardened steel, titanium, and composites. Typically, the electrodes for die sinking EDM are made of copper or graphite.
The main factors that influence the decision for an electrode material are the electrode's conductivity and its resistance to erosion. Graphite has the advantage that it is easier to machine than copper.
However, copper is highly conductive and strong. Brass, an alloy of cupper and zink, is often used for wire EDM or small tubular electrodes.
Contrary to electrodes for die sinking, the wire used for wire EDM does not have to offer good resistance characteristics, as new wire is fed constantly duting the cutting. The main advantage of electrical discharge machining is that it can be used on any material as long as it is conductive.
It is therefore possible to machine workpieces made from tungsten carbide or titanium that are hard to machine with traditional cutting methods. Another advantage of electrical discharge machining is the lack of mechanical force put into the workpiece. Fragile outlines are easier to produce because there is no high cutting force needed to remove the material.
EDM also allows for shapes and depths that are impossible to reach with a cutting tool. Especially deep processing where the tool length to diameter ration would be very high, is a usual application for EDM. Sharp internal corners, deep ribs and narrow slots are other specialities of electrical discharge machining. Another argument for using EDM is that the surface finish is usually better than with traditional methods.
Electrical discharge machining produces surfaces with a fine finish and high precision. Moreover, EDM allows users to machine hardened workpieces. Whereas other machining techniques need to be executed before the workpiece is hardened with heat treatment, electrical discharge machining can be applied on the hardened material as well. Thus, any potential deformation from heat treatment machining can be avoided.
However, there are numerous examples where electrical discharge machining is not the right solutions. EDM is a high precision machining method. EDM is a rather slow method compared to traditional machining. Material is repeatedly removed from the workpiece by a series of high-frequency sparks, precisely cutting out the desired shape. Wire EDM otherwise known as wire erosion, is commonly used for the production of extrusion dies.
It cuts using the same mechanism as die-sinking, however, the die is replaced with a very fine electrically charged wire. This machining method is comparable to a cheese cutter, making a two-dimensional cut in a three-dimensional part. The cutting wire is burnt during the machining process so fresh wire is continuously replaced from an automated spool to ensure precise cutting. The diameter of the wire typically ranges from 0.
As the name implies Hole drilling EDM is used to machine holes. However, compared to traditional hole drilling methods, this technique can accurately machine extremely small and deep holes that don't require deburring. This method also uses the same fundamental principles as die-sinking EDM, though the cut is made with a pulsing cylindrical electrode that moves deeper into the workpiece as the material is removed.
This method has been key to the advancement of high-temperature turbine blades, as it allows for very intricate cooling channels to be manufactured inside the turbine blades.
One of the main advantages of electrical discharge machining is that it allows for shapes and depths to be cut which would be impossible using traditional machining methods. These include features such as undercuts and perfectly square internal corners, making it an ideal method for producing an inside corner during CNC machining.
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