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Transcript of When to Edm July08
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7/01/08
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
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+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.
+
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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
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Each discharge creates a crater
10m
m
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+
+
-
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
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+
-
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
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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)
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WIRE EDM SYSTEM
Wire chopper
Wire spoolWire basket
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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
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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
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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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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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
WHEN?INTERMITTENT CUTS
WHY?NO CONTACTNO FORCE
EXAMPLES?- ENGINE MOUNTS- FORMULA 1 REARHOUSING SUPPORT
Wire + Sinker
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WHEN TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
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 TO EDM BY GEOMETRY
WHEN?ANGLED CUTS
WHY?ABILITY TO 3D ORBITIN SPACE, NO FORCEBETWEEN PIECE/TOOLAT AN ANGLE
EXAMPLES?SUBGATES
Sinker
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WHEN TO EDM BY GEOMETRY
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 TO EDM BY MATERIAL
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 TO EDM BY MATERIAL
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 TO EDM BY MATERIAL
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 TO EDM BY MATERIAL
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 TO EDM BY MATERIAL
WHEN?EXPLOSIVE OR FLAMMABLEMATERIALS
WHY?
EDM TAKES PLACE UNDERWATER
EXAMPLES?MAGNESIUM
Wire
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WHEN TO EDM BY MATERIAL
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.
WHEN TO EDM BY PROCESS REPLACED
WHEN TO EDM BY PROCESS REPLACED
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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
WHEN TO EDM BY PROCESS REPLACED
WHEN TO EDM BY PROCESS REPLACED
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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 BY PROCESS REPLACED
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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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
AccuracyPerformanceAutonomyFlexibilityAutomation
AccuracyPerformanceAutonomyFlexibilityAutomation
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
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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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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Glossary of EDM Terms
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.
Glossary of EDM Terms
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Glossary of EDM Terms
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
Glossary of EDM Terms
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Glossary of EDM Terms
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.
Glossary of EDM Terms
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Glossary of EDM Terms
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
http://www.agiecharmilles.us/sales/index.cfmhttp://www.agiecharmilles.us/sales/index.cfm