EDMing

The efficiency of a die-sinker EDM operation can be enhanced by automating at least part of the work handling or tool handling. This article describes the automation that is available, from the simplest electrode grippers to fully automated toolchanging systems.

Copper is difficult to EDM because of its high thermal conductivity. This article discusses the electrodes and machine settings to use for this demanding task.

With wire EDM, the properties of the wire will have a large impact on the performance of the operation as well as the ease of rethreading. This article discusses the properties that ensure a good spark and reliable performance even when cutting at an angle. Real-world examples are given of users who have improved their operations by changing the type of wire they were using.

EDM cutting conditions change throughout the cutting process as the part thickness and the level of dielectric contamination fluctuates. This article describes an experimental setup that can monitor these fluctuations and adjust the EDM's settings to maintain an optimal spark.

EDMing removes material at such high temperatures that the process produces metallurgical changes in the material surrounding the cut. This article discusses the various surface effects and how they can be detected and measured. It also reviews the different methods for correcting or removing the surface flaws and roughness caused by EDMing.

This report details the results of a test of graphite electrodes. The test compared the performance and machinability of three graphite grades, ranging from an inexpensive coarse grade to a relatively costly ultrafine grade.

The more sophisticated die-sinker EDMs on the market today possess enough intelligence to monitor cutting conditions and make necessary adjustments on the fly. This article describes the technology that drives these smart machines and the "fuzzy logic" they use to maintain an optimal spark.

Graphite electrodes are extremely difficult to machine because of the material’s abrasiveness. This article explains why it takes an endmill with a CVD diamond coating and multiple flutes to cut graphite without wearing tool quickly.

Adequate flushing is needed to keep EDM wires from breaking. This article explains why wires break, and how dielectric fluid delivered with sufficient flow and pressure can prevent these failures from occurring even in less than ideal conditions.

To produce graphic electrodes for EDMing large cavities, shops sometimes must machine the piece in smaller sections and bond them together. This article explains how to build and use a bonded graphite electrode so that a ridge at the electrode’s bond line can be avoided.