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EDM DICTIONARY

CHARMILLES, THEFIRST 50 YEARS

WHEN TO EDMPRESENTATION

CHARMILLES USAOFFICE LOCATIONS

FIND YOUR LOCALCHARMILLES

REPRESENTATIVE

EDMS FOR SCHOOLS

HOW TO PROMOTECAREERS IN TOOLING

AND MACHININGEDMS FOR SHOPS

CHARMILLES EDMPRODUCT LINES

http//www.agiecharmilles.us

CUSTOMERCASE STUDIES

CONVENTIONALVS WEDM

GENERAL MECHANICS
http://charmilles%20the%20first%2050%20years_new.ppt/#-1,1,Slide%201http://charmilles%20the%20first%2050%20years_new.ppt/#-1,1,Slide%201http://wedm%20vs%20conventionnal%20machining_e_new.ppt/#-1,1,%E1%83%AFnventional%20Machining%20or%20EDM%20?%E2%80%80http://wedm%20vs%20conventionnal%20machining_e_new.ppt/#-1,1,%E1%83%AFnventional%20Machining%20or%20EDM%20?%E2%80%80http://general%20mechanic%20jan%202004_new.ppt/#-1,1,Slide%201http://general%20mechanic%20jan%202004_new.ppt/#-1,1,Slide%201http://wedm%20vs%20conventionnal%20machining_e_new.ppt/#-1,1,%E1%83%AFnventional%20Machining%20or%20EDM%20?%E2%80%80http://charmilles%20the%20first%2050%20years_new.ppt/#-1,1,Slide%201


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Harry Moser

ChairmenAgieCharmilles

WHEN TO EDM:The first part of this presentation

provides a brief educationaloverview of the Electrical DischargeMachining Process (EDM)

Second, a detailed analysis ofWhen,Why and Where EDM canprovide a huge benefit in the

engineering, design andimplementation of the overall toolmanufacturing process.

I hope you enjoy the show!

WHEN TO EDM TM


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WIRE SINKER

WHEN TO EDM TM


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THE ORIGIN OF EDM

The origin of electrical discharge machining goes back to 1770,when English scientist Joseph Priestly discovered the erosiveeffect of electrical discharges. In 1943, Soviet scientists B.Lazarenko and N. Lazarenko had the idea of exploiting thedestructive effect of an electrical discharge and developing acontrolled process for machining materials that are conductors ofelectricity. With that idea, the EDM process was born.

Mr. & Mrs. Lazarenko at the presentationof the Eleroda D1atthe EMO exhibition in Milan Italy.

First industrial EDM machine in the world.

Mrs. Lazarenko


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THE ORIGIN OF EDM

The Lazarenkos perfected the electrical discharge process, whichconsisted of a succession of discharges made to take place betweentwo conductors separated from each other by a film of non-

conducting liquid, called a dielectric. The Lazarenkos achieved aform of immortality with this circuit, which today bears their name.Today, many EDMs use an advanced version of the Lazarenkocircuit.

Mr. Jean Pfau the Father of EDMat Charmilles. (photo taken in 2002)

Back in 1952 Mr. and Mrs. Lazarenko shown here meeting withJean Pfau-Physicist at Charmilles who who heads up a team ofengineers to create a machine that will use the erosive effects ofelectrical discharges to cut metals.

50YEARS

LATER


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PROCESS COMPARISON

CHARACTERISTIC MILLING / TURNING EDM

CONTACT YES NO

FORCE YES NO

TOOL/WORKPIECE ROTATION YES NOTNORMALLY

TOOL/WORKPIECE CONDUCTIVE NOT REQUIREDREQUIRED

MATERIAL REMOVAL METHOD SHEAR

MELT/VAPORIZE



+Dielectric (water,oil)

Ionized channel

Piece (Anode)

- Wire orelectrode(Cathode)

Breakdown of the dielectric

An electrical tension is applied between the piece and the wire. When the voltagebecomes high enough, the breakdown of the dielectric occurs and an ionized

channel is created. The dielectric becomes locally conductive and the dischargecan start.

+



Step 1 :An electrical voltage V isapplied. When the voltagebecomes high enough, thebreakdown of the dielectricoccurs.

Step 2 :

An electrical current I circulatesthrough the ionized channel and so

a discharge is created. It is possibleto control the duration and theintensity of the discharge.Two craters appear on theattachment points of the channel.

The controlled discharge

V

V I

I



Each discharge creates a crater

10m

m



+

+

-

Bombardment of the cathode by ions

Plasma

Pressure (> 40 bar)

Force onto molten material

Electrical parameters determine amount of

molten material, gap and surface quality

pressure

Plasma pressure

Moltenmaterial

The plasma



+

-

Interruption of electrical current

Implosion of the plasma

(= fast pressure release)

Boiling & evaporation of molten metal

Ejection of metallic droplets into the

gap

Consolidation of parts of the moltenmetal

on the electrode /part

Particles can move in the gap

Basics: Material removal phase



PRINCIPLE OF EDM SUMMARY

Application of an electricalpotential between wire andworkpiece

Creation of an ionized channel

Spark

Implosion of the plasmachannel

Material ejection

Temperatures: 10.000 -20.000 C

Pressures app. 40 bars

Energy density app.1011 - 10 14 W/m2

Temperature gradients108 0C/m109 0C/s


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WIRE EDMSYSTEM


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WIRE EDM

Generator cabinet(Fast cutting, 37 Sq.In./hr)

Wire supply(0.004 to 0.013 diam.)

Submerged worktank(Thermal stability)

CNC control(WIN NT, Touch screen)



WIRE EDM SYSTEM

Wire chopper

Wire spoolWire basket



The Wire EDM System

Wire diameters from: 0.001 to0.012Coated or Brass wires specificfor either speed, accuracy or

tapers

0 tolerance

closed wire guidesfor accuracy



What is a ROUGH & FINISH Cut?

ROUGH CUT:Rough surface finishLarge particles (chips)

ROUGH CUT:Rough surface finishLarge particles (chips)

Wire

Spark

Wire

OFFSET

FINISH CUT:FIne surface finishSmall particles (chips)

FINISH CUT:FIne surface finish

Small particles (chips)

PART

PART



Flushing

Lower Nozzle

Upper Nozzle

Direction of wire travel

Path of chips going back out

Cut-away view of

part being machined

First, there are 3 thingsyou must learn about EDM:

1. Flushing

2. Flushing3. Flushing


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PILOT EXPERT SYSTEM

Pilot Expert - Maximizes speed whilemaintaining wire stability through varyingpart height and flushing conditions.


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Corners

Sharp corners are no problem with EDM

Conventional Corner EDM Corner


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Steel extrusion die for fibers

Slot width: 0.002Min. inner radii: 0.0001Total form diameter: 0.080


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GF AgieCharmillesFeb. 19th 2007

Wire EDM Performance History

-200%

0%

200%

400%

600%

800%

1000%

1975 1980 1985 1990 1995 2000 2005

Travel

Price

Speed

Performance vs Price 1978 to 2002


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DIESINKER EDMSYSTEM


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Die Sinking Principle


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DIESINKINGEDM


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CNC / Generator(operator console / spark generator)

Electrode changer(automatically change electrodes)

Automatic door(easy access)

Flushing control(removes particles in the gap)

DIESINKER


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Many die-sinkingapplication fields


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DOWN & ORBITING BASICS

DOWNStraight down Z-axis burn using max. power in what is

called roughing mode. The goal is to remove materialquickly. Electrode wear of the Graphite material couldbe from 0.001 to 0.0015 per side

ORBITING 45XY axes translation with low power settings in what iscalled finishing mode. Orbiting provides consistentsurface finish, even wear, and maintains perfect round

geometry or sharp details depending on the orbitingcycle chosen. Electrode wear of the Graphite materialcould be as low as 0.1%


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Machining Cycles

VECT HELIC CONE SPHERE

DOWN ORB ANGUL EXPAN


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Hole Drilling EDM

0.3 mm (0.012)0.5 mm (0.020)0.8 mm (0.032)1.0 mm (0.040)1.2 mm (0.048)1.5 mm (0.060)1.8mm (0.072)2.0 mm (0.080)2.5 mm (0.100)3.0 mm (0.120)

High Speed hole drillingwith coreless electrodes

Diameters


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Lets take a look at otherinstances where EDM is an

alternative solution .

For years the EDM process has been utilizedin making Dies and Molds. There are otherareas where EDM excels in the manufacturing

of specialized components.


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WHEN TO EDM BY GEOMETRY

WHEN?VERY THIN WALLS

WHY? NO CONTACT NO FORCE

NO DEFORMATION

Wire + Sinker

EXAMPLES?- SURGICAL TOOLS

- SATELLITE COMPONENTS- INERTIAL GUIDANCE- MICROWAVE HORNS

- HONEYCOMB

This satellite structural component was wirecut from solidCAL-4V titanium by Numerical Precision, Inc., Wheeling,

Illinois.


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Honeycomb

Honey comb or rib shape-WEDM makes it easy to machinedeep and thin walls in copper orgraphite.

Complex shapes-Any 4 axes shape can be cut.This reduces the number ofelectrodes needed for the moldand therefore the time and costto do it.


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WHEN?INTERNAL RADII LESS THAN1/32 PARALLEL TO TOOL AXIS

WHY?RADIUS IS AS SMALL AS

THE SPARK GAP.GENERALLY TOOL IS NOTROTATED

EXAMPLES?- MOLD & DIE COMPONENTS- REPAIR WORK

Wire + Sinker


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WHEN?HIGH RATIOS OF CAVITY DEPTHTO WIDTHS, SLOTS AND RIBS

WHY?NO FORCE MEANS VERY

THIN, LONG ELECTRODESCAN BE USED

EXAMPLES?

- FLEXURES- COLLETS- JET ENGINE BLADE SLOTS- MOLD COOLING RIBS- REINFORCING RIBS Wire + Sinker


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WHEN?NON-ROUND CAVITIES &OPENINGS

WHY?ELECTRODES DONT

HAVE TO ROTATEEXAMPLES?- FUEL METERING VALVES

- PRINTER COMPONENTS- MOLDS & MOLD REPAIRS

Wire + Sinker


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WHEN?INTERMITTENT CUTS

WHY?NO CONTACTNO FORCE

EXAMPLES?- ENGINE MOUNTS- FORMULA 1 REARHOUSING SUPPORT

Wire + Sinker


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WHEN?VERY SMALL PARTSEX. 0.25 CUBE

WHY?EASY TO FIXTURE SINCE

NO FORCE OR VIBRATION

EXAMPLES?

- DENTAL FIXTURES- MEDICAL CLAWS- WATCH PARTS

Wire + Sinker


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WHEN?RECESSED CUTS

WHY?CUTTING TOOLS COULDNTREACH CUTTING AREA OR

GENERATE DESIREDSHAPE

EXAMPLES?- KEYWAYS- BOTTLING INDUSTRY

Wire + Sinker


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Bottle Cap


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WHEN?WOULD HAVE TO MAKE ASPECIAL TOOLCOSTLY.

EDM IS A BETTER IDEA FORONLY 10-20 PARTS.

WHY?

ELECTRODES ARE LESS $THAN SPECIAL CUTTINGTOOLS AND EASY TO MACHINE.

EXAMPLES?-THIN RIBS WITH CONTOUREDSHAPE.-REPLACE BROACHING WITH EDM. FOR SMALL

QUANTITIES NO NEED FOR STAMPING DIE.

Wire + Sinker


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WHEN?ACCURACIES THAT AREDIFFICULT TO HOLD,

MAINTAIN AFTER HEATTREATING, STRESSRELIEF, ETC.

WHY?CAN EDM CONDUCTIVEMATERIAL OF ANY HARDNESS

EXAMPLES?MOLD THAT NEEDS TO BE HEAT TREATED,ROUGH MACHINED, FINISHED WITH EDM.

STEEL TO STEEL PARTING LINE. Wire + Sinker

Hardened Steel 35NDC16,

185 daN/mm2, 52 HRc

Characteristics of the mold


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WHEN?DIFFERENT GEOMETRY AT TOPAND BOTTOM

WHY?WIRE EDM CUTS RULED

SURFACES WITH SIMPLERPROGRAM + MACHINE THANMILLING.

EXAMPLES?- JET ENGINE BLADES- PLASTIC EXTRUSION DIES

Wire


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WHEN?COMPLEX SHAPES

WHY?EASIER TO PROGRAM BECAUSEYOU ARE USING A TOOL OF

CONSTANT DIMENSION INSTEADOF A VARIETY OF DIFFERENTDIAMETER MILLING CUTTERS.

EXAMPLES?EXTREME TAPERS

Wire


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WHEN?REQUIRES MULTIPLECOMPONENT ASSEMBLIES

WHY?USE TAPER OR RECESS

OR DEPTH: DIAMETERCAPABILITY TO MAKEIT ONE PIECE.

EXAMPLES?EXTRUSION DIES

Wire + Sinker


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WHEN?ANGLED CUTS

WHY?ABILITY TO 3D ORBITIN SPACE, NO FORCEBETWEEN PIECE/TOOLAT AN ANGLE

EXAMPLES?SUBGATES

Sinker


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WHEN?REQUIRES MANY DIFFERENTMACHINING PROCESSES

WHY?EDM CAN GENERATEALMOST ANY SHAPE IN

ALMOST ANY CONDUCTIVEMATERIAL

EXAMPLES?

GENERAL MECHANICS PARTSAVE TIME & LABOR TOTRANSFER BETWEEN

OPERATIONS/PROCESSES wire

OneoperationwithWEDM


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WHEN TO EDM BY MATERIAL

WHEN?HARDNESS ABOVE RC 38:HARDENED STEEL, STELLITE,

TUNGSTEN CARBIDE

WHY?

EDM VAPORIZES MATERIALRATHER THAN CUTTING IT.

EXAMPLES?- DIES- GRINDING TOOLS

Wire + Sinker

These carbide samples are courtesy ofL.H. Carbidelocated in Fort Wayne Indiana.


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WHEN?TOUGHNESS: INCONEL, MONEL,HASTALLOY, NITRALLOY,

WASPALLOY, NIMONIC, UDIMET.

WHY?EDM IS NON CONTACT;

THEREFORE, NO ADHESION OFWORKPIECE TO TOOL.

EXAMPLES?

- MAGNETIC READER HEADS- ARTIFICIAL JOINTS- TURBINE BLADES

- CAR ENGINE PROTOTYPES Wire + Sinker


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WHEN?TENDS TO LEAVE TOUGHBURRS WHEN MACHINED

CONVENTIONALLY

WHY?

VAPORIZED MATERIAL ISFLUSHED AWAY LEAVINGNO BURR.

EXAMPLES?- COPPER ELECTRODE- SURGICAL TOOLS

Wire + Sinker

Multi-operation production parts. Copper andstainless steel shown. Any conductive material canbe cut burr-free and accurately.Courtesy of X-axct Wire located in Menomonee Falls

Wisconsin.

Medical components. Combination small holeEDM (.013 diameter) and wire EDM.

MEDICAL NO BURRS


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MEDICAL- NO BURRS0.001 wire slot


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WHEN?FRAIL/FRAGILECANT TAKE STRESS OF

MACHINING

WHY?

- NO CONTACT- NO FORCE

EXAMPLES?

- PRINTER HAMMER- GRAPHITE ELECTRODES- HONEYCOMB

- LEAD FRAME DIE Wire + Sinker


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Lead Frame Die


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WHEN?EXPENSIVE MATERIAL

WHY?LOWER CHIP: WORKPIECEMASS RATIO. SLUGS AREREUSABLE. CHIPS AREONLY RECYCLABLE.

EXAMPLES?- DENTAL FIXTURES- ENDOSCOPIC CUTTERS

- HIGH ALLOYS Wire + Sinker


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WHEN?EXPLOSIVE OR FLAMMABLEMATERIALS

WHY?

EDM TAKES PLACE UNDERWATER

EXAMPLES?MAGNESIUM

Wire


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WHEN?MATERIAL WITH HAZARDOUSDUST PARTICLES

WHY?

PARTICLES ARE FLUSHEDAWAY TO THE FILTER.REDUCED RISK OF FUMES

EXAMPLES?BERYLLIUM COPPER

Wire + Sinker


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GRINDING:- FORM- CRUSH

- JIG

EDM ALLOWS UNATTENDED MACHINING, LESSEXPENSIVE DESIGN AND SIMPLIFIEDOPERATION

DIES, POWDER METAL DIES, PUNCHES, COREPINS, DOWEL HOLES, etc.

WHEN WHY

EXAMPLES:

CONVENTIONAL:- Several steps- Several tools- Several machines

EDM:- Only one operation- Only one tool- Only one machine

WHEN TO EDM BY PROCESS REPLACED


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WHEN WHY

EXAMPLE:

2+ AXIS MILLING CAN SLAB OFF LARGE SLUGS INSTEADOF PILES OF CHIPS.




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WHEN WHY

EXAMPLES:

ACID ETCHING ORPOLISHING TO

ACHIEVE TEXTUREDFINISH

ELIMINATE ETCHING OR POLISHINGTHEREFORE REDUCE # OF

OPERATIONS, TIME, AND COST.

CONTAINERS- BEVERAGE- FOOD- PERFUME- PHONE MOLD




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SHORT RUNSTAMPING(< 5,000 PIECES)

NO NEED TO MAKE ADIE SET.

SEWING MACHINECOMPONENTS,PROTOTYPES

WHEN WHY EXAMPLES

BROACHING(LOW VOLUME)

LOW COST TOOLING.

SLITTING ORSLOTTING

ELIMINATES BURRSAND BLADE WEARPROBLEMS.

SPLINESGEAR TEETH

PARTS REQUIRINGCOMPLEX EXPENSIVEFIXTURING WITHCONVENTIONAL

MACHINING

NO CONTACT NOFORCE MEANSSIMPLE FIXTURING


WHEN TO EDM LIMITATIONS BY SHAPE


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CHARACTERISTIC WIRE SINKER

THINNEST WALL 0.005 0.002

MINIMUM

- INTERNAL RADII 0.0008 0.001

- EXTERNAL RADII SHARP SHARP- SLOT WIDTH 0.0016 0.0004- HOLE DIAMETER 0.0016 0.0006 (MICROHOLE

TAPER

- MAX. ANGLE +/- 45 N/A- MAX. HEIGHT/ANGLE 30 TO 16 HIGH N/A

HOLE DEPTH TO DIAMETER RATIO- CONVENTIONAL N/A 20:1- SPEC. SMALL HOLE N/A 900:1- MICROHOLE N/A 10:1

RECESS DEPTH- FROM ROUND ENTRY N/A 1/2 HOLE DIAM. - 1/2 ELECTRODE

SHANK DIAM.

- FROM STRAIGHT ENTRY N/A HOLE WIDTH - ELECTRODESHANK DIAM.

WHEN TO EDM LIMITATIONS BY SHAPE

WHEN TO EDM LIMITATIONS BY OTHER


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CHARACTERISTIC WIRE SINKER

WORKPIECE CONDUCTIVITY AND APPROX. (0.5 - 5) OHM CENTIMETER SAMEFIXTURE MAX.

ACCURACY- CONVENTIONAL +/- 0.000040 +/- 0.0001- MICROHOLE N/A +/-0.0004

SURFACE FINISH VDI 0 VDI -5

MICROINCH 4 MICROINCH 2

TEXTURE FINISH RANDOM, UNIFORM TEXTURE ONLY SAME

SURFACE INTEGRITY- RECAST LAYER THICKNESS 20 MILLIONTHS 20 MILLIONTHS- MICRO CRACK LENGTH 20 MILLIONTHS 20 MILLIONTHS

WHEN TO EDM LIMITATIONS BY OTHERCHARACTERISTICS


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EXACT

DIFFICULT

MACHINING

THE END


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65GF AgieCharmilles

THE END


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The U.S. and Worlds Largest Supplier of


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The U.S. and World s Largest Supplier ofEDMs for the Tooling & Machining Industries

WIRE EDM PRODUCT LINE


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WIRE EDM PRODUCT LINE

Price/Perfo

rmance

Size

Axes XY

PROGRESS

V2

CLASSICV2

CLASSICV3

PROGRESS

V3

VERTEX /F

PROGRESS

V4

VERTEX 3 / 3FVERTEX 2 / 2F

CHALLENGE V2 CHALLENGE V3

FI 2050 TW FI 6050TW

FI 240CC

FI 440CC

FI 640

CC

FI 240SLP

FI 440SLP

AutomationFlexibilityCutting performanceErgonomicsControl Unit

Cutting perfomanceErgonomicsControl unitFlexibilityRunning costs

Running costsFlexibilityErgonomicsCutting performanceControl Unit

220 x 150 350 x 250 500 x 350 700 x 500

AccuracyCutting performanceAutonomyFlexibilityControl unit

DIE SINKER PRODUCT RANGE
http://kick%2007%20progress.ppt/http://../CT%20files/ID_PRODUCTS%20WEDM_US.ppthttp://kick%2007%20classic%20in%20usd.ppt/http://kick%2007%20challenge.ppt/http://kick%2007%20vertex.ppt/http://../CT%20files/ID_HEW_US.ppt


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DIE SINKER PRODUCT RANGE

Size

Axes XY

AccuracyPerformanceAutonomyFlexibilityAutomation

EconomyFlexibilityPerformanceAutonomyAccuracy

HYPERSPARK

2 HS

SPIRIT 2 SPIRIT 3 SPIRIT 4

HYPERSPARK

3 HS

HYPERSPARK

EXACT 2 HS

HYPERSPARK

EXACT 3 HS

Price/Performance

220 x 150 350 x 250 500 x 350 700 x 500

FM20 ZNC

FO23P

FO35P

FO350

()(S)FO550

()(S)

FO350

FO53P



SCHOOLS (College and School Instr ctors)
http://../Documents%20and%20Settings/EOstini/Desktop/GF/AgieCharmilles/CT%20files/DS_Product_Range_2006.ppthttp://../Documents%20and%20Settings/EOstini/Desktop/GF/AgieCharmilles/CT%20files/SPEED_EDITION_JAN07.ppthttp://../Documents%20and%20Settings/EOstini/Desktop/GF/AgieCharmilles/CT%20files/DS_Product_Range_2006.ppthttp://../Documents%20and%20Settings/EOstini/Desktop/GF/AgieCharmilles/AGie%20files/Presentation%20Kick%20Off%20North%20America%2019-21.207/Kick%20NA%2007%20Spirit%20.ppthttp://../Documents%20and%20Settings/EOstini/Desktop/GF/AgieCharmilles/AGie%20files/Presentation%20Kick%20Off%20North%20America%2019-21.207/AGIETRON%20TOP%205%20Hyperspark/TOP%205%20Hyperspark/Kick%2007%20Hypersaprk.ppt


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New Jersey California

EDM Machines for Schools

Phone: 800-CTC-1EDM Ext. 170

WHAT ELSE CAN YOU GET FROM CHARMILLES TO HELPYOU?

- School prices on new and used

Charmilles EDMs

- Help in recruiting students

- Information on NIMS certification

Contact your AgieCharmilles Distributor

www.agiecharmilles.us

HOW TO GET IT?

SCHOOLS (College and School Instructors)

SHOPS


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Illinois New Jersey California

EDM Machines for ShopsPhone: 800-CTC-1EDM Ext. 115

WHO ARE YOU?

WHAT ELSE CAN YOU GET FROM

CHARMILLES TO HELP YOU? HOW TO GET IT?

Charmilles EDM operators &

Programmers

Basic & Advanced Operator Training www.charmillesus.com/training/training.cfm

Charmilles EDM job shops, CNC job

shops and tool rooms inside large

companies

Help promoting your services to your

current and prospective customers. We

will help you present When to EDM as a

way of promoting your services.

Contact your Charmilles Distributor.

www.charmillesus.com/salesnet.cfm

Manufacturers with a workpiece that has

manufacturability problems

Help you evaluate if When to EDM is

now.

-Call your Charmilles distributor.

-E-mail part, photograph, print, description

of the manufacturability problem to

[email protected] or

[email protected].

A manufacturer that wants to justify anEDM for in-house use.

Provide EDM ROI spreadsheet to performthe analysis, based on the economics of

your application.

Contact your Charmilles distributor.www.charmillesus.com/salesnet.cfm

A manufacturer that wants to find an EDM

job shop to make your parts.

Provide access to the top EDM job shops

in the U.S. and Canada.

Contact your Charmilles distributor

www.charmillesus.com/salesnet.cfm

SHOPS

CAREERS


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Illinois New Jersey California

How to Promote Careers in Tooling & MachiningPhone: 800-CTC-1EDM Ext. 170

CAREERS

CAREERS


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CAREERS


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Glossary of EDM Terms


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Amperage -In EDM, the amount of average current measured during the cut.Arc - A continuous flow of electrical current. This continuous flow causes

damage to both the electrode and work piece.Blind hole - Any cavity that has a bottom surface and that doesnt connect with

any other openings.Capacitor - An electrode component that stores an electrical charge. In EDM it is

used frequently for cutting metals with high melting temperatures and duringfine finishing cycles.

Carbon - An abundant, naturally occurring element. Graphite is a form of theelement carbon.

Core - The stalagmite caused by EDMing with an electrode drilled with holes forflushing in it.

Corner wear - The measurement of wear on the corners of the electrode.Cubic inches per hour (in3/hr) - The unit of measure used to describe the metal

removal rate of sinking type EDMs.



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DC arcing - same as ARC.Deionization - Bringing the dielectric to a non-conductive state.Dielectric fluid - In EDM, a non-conductive fluid used to control the sparking condition. Also

used to cool and remove the cutting debris from the erosion area.Dielectric strength - measurement of how resistant the fluid is to current flow.

Duty cycle - the percentage of on-time to the sum of on-time and off-time.EDM - (Electrical Discharge Machining) - A metal removal process using electric sparks to

erode conductive materials.Electrode - The cutting tool in EDM.Electrode growth - A plating action during certain settings causing material to build up on the

electrode, causing an increase in size.End wear - A measurement of wear on the frontal plane of the electrode.Filtering - In EDM, a process of removing the cutting debris from the dielectric fluid.Finish - The surface texture produced



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Flush pot - A multipurpose box-like fixture used to hold the work piece or electrode that allowsflushing to pass through. Suction or pressure flushing can be used.

Flushing - The process of removingthe cutting debris from the cutting area.

Gap -(Spark gap) - The distance between the electrode and the work piece where the spark

occurs.Gap voltage - A measurement of voltage during the EDM process.Generator - A term used to describe

the EDM power supply.Injection flushing - Pressure type flushing where dielectric fluid is forced into the cutting area

through various means.Ionization - The phenomenon by which the dielectric between two points on the electrode and

work piece becomes electrically conductive.Microsecond (s) - One-millionth of a secondOff-time - Length of time that current is off. Measured in microseconds.On-time - Length of time current is on. Measured in microseconds.Overcut - measurement difference between the dimensions of the cavity EDMed and the

dimensions of the electrode used to cut the cavity.



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Peak current - Maximum current (amperage) available.Average amperage = A : (On Time + Off Time)

e.g. 50 Amp machine 50% On time 50% Off time = 25average Amps.

Pulsator - A mechanical device built into most EDMs for the purpose of moving the electrode in and out of thecavity in timed movements to aid flushing.Reverse polarity - A process that reverses the flow of current.Vacuum flushing - A flushing method using suction rather than injection.Undersize - A term used to describe the difference between the finished cavity size and the electrode size.*Some definitions were taken from the POCO Graphite Technical Manual


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CASE STUDY 1


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CASE STUDY 1

An example of a product produced because of EDM's ability to

eliminate special cutting tools is this fin deployment actuatorhousing for a missile. Using EDM eliminated the need forexpensive broach tooling to form the through T-slot configurationinto this 15-5PH forging.

Part example supplied by NumericalPrecision in Wheeling, Illinois

CASE STUDY 2


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CASE STUDY 2

Classic Die, a shop in Grand Rapids, Michigan, produces thisinjection mold using the fine-grain graphite electrodes above. RamEDM often provides the only way to produce such intricate moldcatities (this mold has been cross-sectioned to reveal its taperedhelical slots), as well as other workpieces which have deep slots ornarrow ribs. The components produced in this mold are 2.75 incheslong and are used in medical instruments for heart surgery.

Part example supplied by Classic Die in Grand Rapids Michigan.

CASE STUDY 3


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The surface finish of the fitting surfaces madeby WEDM allow air venting during the plasticinjection phase. Air can escape but notplastic.This is very useful to help plastic fill the

ribs. The reinforcement ribs are complexshapes. They can be machined separately andpress fit.

The reinforcement ribs of this TV casing are not machineddirectly on the mold core. They are added.(inserted)Open cavities to receive them are WEDM cut.

TV MOLD: VENT HOLE FOR REINFORCEMENT RIBS

CASE STUDY 3

CASE STUDY 4


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CASE STUDY 4

WEDM makes it easy to machine any kind of gear with high accuracy.

No need to use dedicated machine to cut cylindrical or tapered gears.

Gear modification is fast and easy.

Wire EDM reduce lead time to produce plastic gears.

Plastic gears Gears for Formula-1 race team

Case Study #5:Gear Wheel machined with MicroWEDM


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Height of structure: 0.240

Outer diameter: 0.020

Number of teeth: 8

Wire: 20 m, (0.00078) tungsten 1 cut

Material: 1.2343 (X38CrMoVS_1)

Albert-Ludwigs-UniversityFreiburgChair of Process TechnologyFaculty of Applied Sciences

WEDM


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FIND YOUR SALE REPRESENTATIVE


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FIND YOUR SALE REPRESENTATIVE

http://www.agiecharmilles.us/sales/index.cfm
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