Download - EDM Technical Article...EDM also has the ability to cut very hard metals with impunity that are challenging to machine with other processes. There are three basic types of EDM processes

CompassPrecision,LLC

4600WestinghouseBLVD.•Charlotte,NC28273•Phone704-504-3330www.compassprecision.com

EDMTechnicalArticleByPaulLutz,KeithFelts&PatrickReynoldsAtonepointaninfrequentmachiningmethod,EDMhasgrowninpopularityoverthelasthalfcenturytobecomeanimportantaspectinthesuccessofAdvancedMachining&Tooling,LLC.Unlikeothertypesofmachining,EDMcreatesadesiredshapebyusinganelectricaldischargeorsparks.Thismethodcancreateintricatecontoursandcavitiesthatareusuallydifficulttomake.EDMalsohastheabilitytocutveryhardmetalswithimpunitythatarechallengingtomachinewithotherprocesses.TherearethreebasictypesofEDMprocesses--sinkerEDM,wireEDMandsmall-holeEDMdrilling.Allthreeworksimilarlywithsparkerosioncreatingthedesiredshape.ThemostconventionalofthethreetypesofEDMprocessesissinkerEDM,whichisalsowidelyknownasram,cavityorconventionalEDM.Inthisprocess,sparksfromasinkerelectrodethat’sbeenpreviouslymachinedintoanexactimageofthecovetedshapecausethemetaltoerodefromtheworkpieceinordertocreatethedesiredpart.Thetwoelectrodesnevertouch,asadielectricliquid,whichcontinuouslycirculatesaroundthetwoelectrodesandflushesawaythescrap,separatesthem.

CompassPrecision,LLC4600WestinghouseBLVD.•Charlotte,NC28273•Phone704-504-3330

www.compassprecision.com

WireEDMiscomparable,butasthenameoftheprocesswouldindicate,awireisusedtoprovideoneoftheelectrodes.Sparksfromthewirejumptotheworkpieceanderodemetaltocreatethedesiredpart.Thisprocesstypicallyoccursindeionizedwater.Insmall-holeEDM,brassorcoppertubesarerotatedwhileloweredintothematerial.Again,thetubenevermakescontactwiththeworkpiece,butthesparksfromthetubeerodethemetaltocreatethedesiredpart.AdvancedMachiningspecializesinthefirsttwotypesofEDMprocesses--sinkerandwire.Intotal,EDMprocessingaccountsforasignificantpercentageofthecompany’ssalesonayearlybasis.AdvancednowhasfiveAgieCharmillesEDMunits,manufacturedbyGFMachiningSolutions,tosupportthispartofitsbusiness,anditcontinuestogrowinthisarea.Latein2019,thecompanyacquiredanadditionalsinkerEDMmachine,andearlyin2020,itaddedanotherwireEDMunit.ThesefivemachinesarepartofalargefamilyofCNCmachinesdeployedonadailybasisatAdvanced.Thecompanyalsopossessessix3,4,and5-axisverticalmachiningcentersandtwoturningcenters,onewithlivetoolingformulti-taskingmillingandturning.ThesecapabilitiesarecontinuingtohelpAdvancedgrowintheCNCmachiningindustry.PerformingthewireandsinkerEDMprocessespermitsAdvancedtocreatesometrulyuniqueparts.SomeofthemorerareshapesAdvancedMachiningconstructsonaday-to-daybasisaremachinedfrommaterialssuchasInconel,tungsten,titanium,rheniumandindium.Again,thosemetalsaredifficulttomachinewithotherprocesses.

CompassPrecision,LLC4600WestinghouseBLVD.•Charlotte,NC28273•Phone704-504-3330

www.compassprecision.com

Additionally,EDMmethodsallowAdvancedtobeextremelyaccurateandefficient,keepingcoststoaminimumandcustomerspleased.TheshapesandpartsAdvancedcreateshavebecomeextremelyimportanttoitsaerospace&defense,telecommunicationsandmedicalcustomers.AbouttheAuthors

PaulLutz

KeithFelts

PatrickReynolds

PaulservesasAdvancedMachining’sEDM&MaintenanceSpecialistandhasextensiveexpertiseinwireEDM.Hegainedthisknowledgeworking16yearsforGFMachiningSolutions,aleadingmanufacturerofwireEDMequipment,beforejoiningAdvancedMachiningin2014.

Keithco-foundedAdvancedMachiningin1985andhasservedasPresidentsincethen.Heisaleadingexpertinelectricaldischargemachining,particularlysinkerEDM.HepreviouslyworkedasanapplicationengineerforAgieCharmilles,atopmanufacturerofEDMequipmentbasedinSwitzerland.

PatrickisAdvancedMachining’sOperationsManager.Hehasadiversebackgroundinvariousmachiningtechnologies,includinghorizontalandverticalmillingaswellaswireandsinkerEDM.HepreviouslyworkedatseveralothermachineshopsinpositionsofincreasingresponsibilitybeforestartingatAdvancedin2015.