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Hole pop edm

At Holepop, we believe in trust and collaboration when dealing with our customers. Collaboration includes the responsibility to keep our customers well informed about our electrodes, as a customer that knows the strengths and weaknesses of their electrodes stands to gain time and money. This and all of the other different variables encountered in EDM—such as workpiece material and machine settings—can make it difficult to choose the right electrode. With our wide array of electrodes, you will be sure to find one that fits your particular EDM machine or equipment. Brass EDM tubes are used on the largest variety of electrically conductive materials and metals to small hole drill. If you are not quite sure which electrode material to start out with, brass is probably the best bet. Due to the molecular composition of brass, it will remove material at the fastest rates when applied to certain alloys, tool steels, stainless steels and rare metals. Brass is fast at the expense of wear rates. Brass electrodes tend to wear out much faster compared to copper electrodes at the point of spark contact with the workpiece, and this should be taken into consideration on long running hole burns or EDM holes that are very deep. This fast wear rate becomes a particular problem when attempting to burn through stubborn materials such as carbide or tungsten carbide.
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Whether you are an aerospace, medical device, or defense manufacturer, a research laboratory, or a precision job shop, we have the capabilities to fulfill your needs.
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That’s Our Specialty

Makino EDMs stand apart with the intuitive Hyper-i control system, a streamlined and efficient interface that helps you get work done faster. All models use a stationary work table design and a 3-sided rise and fall drop tank for easy automation and enhanced productivity. With pinpoint sub-micron precision and outstanding surface finish, these are ideal for small electronics and micromachining applications. With a focus on high-precision small hole drilling and excellent edge quality, these also have the flexibility to execute standard ram EDM operations. Designed for high-volume production these precise machines achieve the fastest speeds with multi-axis contour machining to produce shaped hole features common to turbine engine components. The Makino BX3 machine is purpose-built for the EDM Drilling demands of high volume production applications of cooling film hole features that are found in Blade and Vane turbine engine components. New machine doubles rough machining rates without increasing manufacturing costs To be competitive in the marketplace manufacturers must continuously identify opportunities to improve efficiency and increase capacity while maintaining the highest level of quality Solutions for suppliers seeking ways to meet new productivity challenges, including increasing demand and shorter lead times. Over the next five years, Original equipment manufacturers OEMs are There is no magic formula for discovering the optimum number of parts that can be placed on your fixture, though a few general rules apply.
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Wire electrical discharge machining EDM is a non-traditional machining process that uses electricity to cut any conductive material precisely and accurately with a thin, electrically charged copper or brass wire as an electrode. During the wire EDM process, the wire carries one side of an electrical charge and the workpiece carries the other side of the charge. When the wire gets close to the part, the attraction of electrical charges creates a controlled spark, melting and vaporizing microscopic particles of material. The spark also removes a miniscule chunk of the wire, so after the wire travels through the workpiece one time, the machine discards the used wire and automatically advances new wire. The process takes place quickly—hundreds of thousands of sparks per second—but the wire never touches the workpiece. The spark erosion occurs along the entire length of the wire adjacent to the workpiece, so the result is a part with an excellent surface finish and no burrs regardless of how large or small the cut. Wire EDM machines use a dielectric solution of deionized water to continuously cool and flush the machining area while EDM is taking place. In many cases the entire part is submerged in the dielectric fluid, while high-pressure upper and lower flushing nozzles clear out microscopic debris from the surrounding area of the wire during the cutting process. The fluid also acts as a non-conductive barrier, preventing the formation of electrically conductive channels in the machining area. When the wire gets close to the part, the intensity of the electric field overcomes the barrier and dielectric breakdown occurs, allowing current to flow between the wire and the workpiece, resulting in an electrical spark.
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Electrical discharge machining EDM drilling is a little more complex than typical chip-removal processes. In EDM work, energy is directed into an electrode and the workpiece is submerged in a dielectric fluid. When the two are separated by a small space—the spark gap—a pulsed electrical discharge from the electrode creates a spark that removes material from the workpiece through a process of melting and evaporation. In typical applications, brass or copper electrodes with the correct finish-hole diameter are used to create holes in the workpiece.

The electrode is charged by the EDM power supply and is fed forward to create the machining feed rate. The power usage and electrode feed rate, as well as the motion of the machine's axes, are all controlled by the machine's CNC. A rotating spindle holds the electrode, and a guide ensures the correct location is held during drilling. As the electrode creates a hole in the material, a high-pressure dielectric flush surrounds it.

This high-pressure flush forces the eroded material to leave the hole quickly, enabling deeper holes to be made. As holes become deeper, maintaining the high-pressure flush becomes even more important because the removed material has farther to travel up the hole.

If flushing conditions are poor, or if the pressure is not high enough, material can build up and will begin acting like an extension of the electrode. If this occurs, sparks will arc across the dielectric fluid and strike the workpiece in an unwanted area. This short-circuit, or DC, arc creates pitting on the workpiece and is the first indicator of poor flushing conditions. In mechanical drilling applications, the tool makes physical contact with the material and is more of a friction proc-ess. The drill can "wander" or "walk" as it makes contact with the workpiece, especially if it is drilling into a concave or convex part.

Prehardened parts can also cause wandering to occur. Hardened metal, material with a hardness of 70 and higher on the Rockwell hardness C scale, can also be drilled with EDM. Alternatively, EDM is a thermal process in which the material is eroded away rather than mechanically cut. The electrode does not come in contact with the workpiece. Proper energy control is important to create a very fine spark.

The smaller the spark, the smaller the hole you can produce. According to Thomas, one of the most common drilling applications for EDMs in the marketplace is the creation of starter holes for wire EDM work. These EDMs, often referred to as "hole poppers," are a special type used almost entirely to make starter holes. However, there are also some production applications in both the aerospace and medical industries. The other type of holemaking EDM is for small, precise holes with diameters as small as 0. In these operations we use oil as a dielectric fluid rather than water," said Thomas.

We can even control accuracy down to 2 microns in some applications. Linear motors allow you to respond to changing conditions very quickly.

When the electrode and workpiece are separated by a small space—the spark gap—a pulsed electrical discharge from the electrode creates a spark that removes material from the workpiece through a process of melting and evaporation. The motion of the EDM's axes will be familiar to anyone who has run a milling machine. Therefore, moving the electrode through the work envelope is pretty basic. However, the control also manages the power supply, spark creation, and automatic electrode feed.

It is necessary to make the correct movements, but far more importantly, it's about controlling the entire process. Power levels are adjusted automatically by the control, which helps improve accuracy and surface finishes. EDMs are adept at creating very small holes in difficult-to-machine materials. For example, when using a 0. The spiral shape, combined with the flushing through the tube, ensures that we don't actually leave any material in the hole.

The two types of EDM drills, hole poppers and precision machines, create holes for different applications and in different diameters. Hole poppers typically create hole diameters between 0. As the electrode enters the workpiece it will begin to wear away. Depending on the material being cut, electrode wear ranges from 50 to percent. For example, at percent wear rate, for every inch eroded, the electrode will wear by 1 in.

By reducing electrode wear, consumable costs are reduced, as is the time wasted changing electrodes. Because electrode wear can vary so significantly, Baeszler's advice is to make sure electrode cost is figured into the job-quoting process. When you use electrodes that are smaller than 0. So make sure to talk to your electrode supplier when you are quoting jobs. The larger-diameter electrodes typically are made of brass and are less expensive. As diameter decreases, the electrodes generally are made of tungsten or carbide and become more expensive.

Also, smaller-diameter electrodes typically wear faster. This means that the smaller the hole, the more expensive it is to create. The control used for EDM can increase the power intensity, which enables faster drilling. However, it also creates more electrode wear. Depending on the application, especially in a production environment when cycle time is extremely important, you can sacrifice a little electrode wear to improve productivity.

This will allow you to preserve the electrode—and consumable costs—by slowing down. For more information, visit www. Now through Sept. Easily access valuable industry resources now. Not yet registered? Sign up. Our Sites. Categories Automation Software. Metal Finishing. Our Publications. Canadian Metalworking From Canadian Metalworking.

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