There are many different types of tooling, the most common being work holding tools. Work holding tools include jigs and fixtures; cutting tools for milling and grinding machines; dies for cold forming, forging and extrusion machines; and welding and inspection fixtures. In this month’s blog, we are going to look at turning.
Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes a helix toolpath by moving more or less linearly while the workpiece rotates. Turning is a form of machining, a material removal process, which is used to create rotational parts by cutting away unwanted material. The turning process requires a turning machine or...Read more
As the cut progresses through the work metal a cavity starts to form. The deeper this cavity becomes, the harder it is for fresh dielectric fluid to get into the cavity to remove debris and quench the work piece and electrode. In order to get smooth, even flow of dielectric through the gap, flushing becomes an essential part of the EDM process.
Good flushing allows the work piece particles and eroded electrode particles to be removed from the gap. Flushing also allows fresh dielectric into the gap. Both are necessary to maintain stable cutting and to prevent arcing.
It is the volume of oil moving through the gap that performs particle removal. Turbulence in the tank would...Read more
EDM machining is considered by most to be a thermal removal process. The most convincing support for this claim is the removal of material from the electrodes by melting and/or vaporization by a thermal process, along with pressure dynamics established in the spark-gap. The spark gap generates an electrical force on the surface of the electrode that removes material.
Electric discharge machining (EDM), sometimes referred to as spark machining, spark eroding, burning, die sinking or wire erosion is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). Material is removed from the workpiece by a series of rapidly recurring current discharges...Read more
Choosing Dielectric Fluid for Sinker EDM Applications
Choosing the correct dielectric fluid for your EDM application is not always as straightforward as it might seem. Many criteria need to be taken into account. Some are obvious, such as degree of metal removal and electrode wear, while others are much more subtle.
Dielectric fluid is a material whose main purpose is to prevent or rapidly quench electric discharges. Dielectric liquids are used as electrical insulators in high voltage applications to provide electrical insulation, suppress corona and arcing, and to serve as a coolant.
A good liquid dielectric should have high dielectric strength, high thermal stability and chemical inertness against...Read more
SINKER EDM BASIC TERMINOLOGY – PART II - FLUSHING
MAR 2018 Blog
It’s been said the 3 most critical things about a good sinker EDM burn condition are flushing, flushing, and flushing. This is still true today but modern machines have built in technologies that assist with flushing even when the operator doesn’t think about flushing. More on these in a bit.
Flushing is a critical part of the EDM process, as it removes contaminated fluid and eroded particles, and replaces them with clean, temperature controlled fluid. This removes contamination from the spark gap that could develop into undesirable conditions like slow, unstable burns, pitting of the work piece, and...Read more
RAM EDM, otherwise known as “Sinker EDM
” or “Plunge EDM
” has been around for over fifty years. Though widely used, there are some who are unfamiliar with certain EDM terminology.
KEY FACTORS OF SINKER EDM
Since Sinker EDM uses electrical energy to remove material, it stands to reason that the make-up of the material will have a direct impact on the rate of removal. This being the case there are three critical things to keep in mind.
• Since machining with Sinker EDM or Plunge EDM occurs by using electrical energy the electrical conductivity plays a key role in how fast the Spark Gap can ionize allowing a spark to...Read more
Electrical Discharge Machining or EDM Machining makes it possible to work with hard metals for which traditional machining techniques are inadequate.
The EDM machining process came into being during the 1770s when it was discovered by an English Physicist name Joseph Priestly, who discovered the effect of electrical discharges on various metals. However, the process was not widely used until 1943 when Russian scientists B.R. and N.I. Lazarenko discovered how to exploit the destructive effects of an electrical discharge technique that could be controlled and used for machining work.
Any conductive material can be machined using Sinker EDM such as aluminum, brass, carbide, copper, stainless steel, tool steels, titanium etc. Sinker EDM is a...Read more
A key area for improvement in EDM operations is the reduction of consumables. New technologies, machine settings and improved material grade limit ram or sinker EDM electrode wear to 0.1% while maintaining productive machining speeds. For wire EDM, new low-consumption technologies reduce the biggest expense—the wire itself—by as much as 50 percent.
With all EDM machines you experience the benefits of designing and cutting complex shapes and tapered holes with hard metals. You can depend that the machine has the capacity to cut exactly what you want.
Sinker EDM machines use an electrode and workpiece submerged in liquids such as oil or dielectric water. A power supply is connected...Read more
November 2017 Blog
Karl Schmidt, QMR/SSBB - Quality Manager
Graphel Carbon Products
This past October, a Japanese company named Kobe Steele was found to be falsifying test records and substituting materials for various genuine metallics used in the transportation industry. Although rare, this can and does happen in the graphite industry.
Graphel Carbon Products has been AS9100 Certified since 1994, and we verify all of our materials and suppliers. We only sell materials that are genuine and verified, and do not substitute. As the Quality Manager here at Graphel, I take my position very seriously,...Read more
Jeff Immelt, previous CEO of manufacturing giant GE recently stated about Artificial Intelligence, “Companies need to become digital to survive - We must turn information into insights and insights into outcomes.”
That implies we have something to think about:
Manufacturing is changing, which isn’t a bad thing. But technology will become difficult to keep up with if we don’t keep an open mind. Though we embrace new technology in some parts of our shop, one trend in particular should be on our radar:
It will dramatically change our industry. However, coming to terms with that fact can be...Read more