What Is Electrical Discharge Machining (EDM) Machinery?
Electrical discharge machining (EDM) machinery is a tool used for melting and processing workpieces using heat generated by an arc discharge, primarily in metalworking applications.
In electric discharge machining, an electrode in a liquid is discharged between the workpiece and the electrode to melt the workpiece through heat. The melted portion is then cooled and dispersed by the liquid. This method enables the precise shaping of hard materials, even when conventional cutting tools are not suitable for the job.
Uses of Electrical Discharge Machining (EDM) Machinery
EDM is employed to process materials that are challenging to work with using traditional methods. It is particularly useful for machining high-hardness materials. Tasks like creating hexagonal holes, keyways, and complex angular machining are not restricted by the limitations of conventional cutting tools.
In screw machining, EDM can be used for post-machining threads in cases where machining was overlooked, and quenching has occurred. It is also suitable for machining small, deep holes that cannot be drilled conventionally. Slanted holes can be easily created, and specimens with microscopic defects (artificial defects) can be produced using EDM. Additionally, EDM is ideal for machining precise, fine gears with high accuracy. Wire EDM, which uses fine wire, can produce clean involute lines and perfectly circular holes at the center.
Principles of Electrical Discharge Machining (EDM) Machinery
In electrical discharge machining, the workpiece is immersed in a highly insulating processing fluid, and it undergoes repeated electrical discharges at a rate of 1,000 to 100,000 times per second. During each discharge, while maintaining a gap of several tens of microns between the electrode and the workpiece, the metal reaches temperatures of several thousand degrees Celsius, causing it to melt.
The processing fluid rapidly cools the molten metal, causing it to vaporize and explode, dispersing it away from the processing surface. The principle of electrical discharge machining involves the removal of material from the workpiece surface as small particles are cooled and dispersed in the processing fluid.
Types of Electrical Discharge Machining (EDM) Machinery
There are three primary types of EDM machinery in use:
- Die-Sinking EDM Machinery
Die-sinking EDM machinery shapes the workpiece by employing electrical discharge between the electrode and the workpiece. An electrode, typically made of materials like copper or graphite, is machined into the inverse shape of the desired object. When the electrode is brought close to the workpiece, electrical discharge occurs, resulting in the workpiece taking on the shape of the electrode. This process can be controlled numerically, enabling complex 3-dimensional machining, and it is often used for producing molds used in resin molding.
- Wire EDM Machinery
Wire EDM machinery utilizes an extremely thin wire, typically with a diameter ranging from 0.05 mm to 0.3 mm, as an electrode for electrical discharge machining. Brass wire is commonly used, and the wire is guided by numerical control (NC) to cut the workpiece into the desired shape. Wire EDM is characterized by the absence of electrode machining and minimal material loss during the process. It excels in machining complex shapes but cannot handle materials that cannot be penetrated. This method is often employed for processing press work dies, among other applications.
- Small-Hole EDM Machinery
Small-hole EDM machinery uses a rod- or pipe-shaped electrode within the processing fluid to melt and remove material while drilling tiny holes. It is capable of drilling holes as small as 0.1 mm in diameter. The electrode and workpiece are processed without direct contact, making it suitable for tasks like creating air vent holes in molds and precision nozzles.
Configuration of Electrical Discharge Machining (EDM) Machinery
EDM machinery typically consists of three key components: the main machining unit, the machining control device, and the machining fluid supply unit.
- Main Body of EDM Machinery
The main machine incorporates the electrode responsible for processing the metal. It is pressed against the workpiece while processing fluid is sprayed from an injection nozzle. An appropriate volume of processing fluid must fill the machining area, and this is achieved by surrounding the area with a processing tank equipped with a liquid-level adjuster.
- Machining Control Device
The machining control device is an essential component of NC machine tools. By inputting data into the machining program, it can ensure the consistent and highly accurate production of machined products.
- Machining Fluid Supply Device
Electric discharge machining relies on the flow of electricity through an insulating gas or liquid, with machining fluid acting as the insulator. Water or oil is typically used as the primary ingredient in machining fluids. These fluids play a critical role in electric discharge machining by providing cooling and removing machining debris.
Additional Information on Electrical Discharge Machining (EDM) Machinery
Features of Electrical Discharge Machining (EDM) Machinery
The most significant advantage of EDM machinery is its ability to process challenging materials with ease. It excels in precision, capable of machining down to a few microns and handling complex shapes.
EDM is a non-contact machining method, eliminating the potential for accuracy defects caused by workpiece deformation. It can swiftly process even thin plates. While traditional cutting processes often leave burrs, EDM produces no burrs, eliminating the need for additional deburring. Moreover, it can accurately machine inside corners, deep grooves, and holes with widths as small as 0.1 mm. However, EDM’s slow machining speed and the need for numerous consumables, such as electrodes, make it less suitable for mass production.