What Is EDM Machining - Electrical Discharge Machining Definition
EDM (Electric Discharge Machining) is a non-traditional metal processing method, also known as electrical discharge machining. It removes material from the workpiece by applying a voltage between the workpiece and the electrode, creating an electrical spark discharge. This processing method is suitable for hard, brittle and difficult-to-machine materials, such as titanium alloys, carbide and ceramics. EDM processing can achieve complex shapes and high-precision processing.
Why Use EDM Machining?
Reasons for using EDM include:
1. High-precision machining: EDM can achieve very high precision and surface quality, and is suitable for manufacturing parts that require high-precision machining.
2. Processing of difficult-to-machine materials: For materials with high hardness and brittleness, such as cemented carbide, titanium alloys, etc., traditional processing methods are difficult to process, but EDM can effectively process these materials.
3. Complex shape processing: For complex-shaped parts, EDM can achieve precise processing without the need for additional molds or tools.
4. Low thermal impact: The heat generated during EDM is very small and will not cause thermal deformation or residual stress on the material. It is suitable for processing parts that are sensitive to the thermal impact of materials.
5. Efficient processing: EDM can process multiple workpieces at the same time, improving processing efficiency.
Types Of EDM Machining
Common types of electrical discharge machining include wire-cut electrical discharge machining,drilling electrical discharge machining,and sinker electrical discharge machining.
Wire cutting machining processes parts through the discharge principle of electric sparks. Connect the workpiece to the positive electrode of the pulse power supply, use molybdenum wire or copper wire as the cutting wire, connect the metal wire to the negative electrode of the high-frequency pulse power supply as the tool electrode, and use spark discharge to cut the processed parts. The pulse power supply provides processing energy, and special wire cutting fluid is used to remove debris generated during processing. Under the action of the electric field, the surfaces of the cathode and anode are bombarded by electron flow and ion flow respectively, causing an instantaneous high-temperature heat source to form in the electrode gap to melt and vaporize local metal. The gasified working fluid and workpiece material vapor expand rapidly instantly. Under the combined action of this thermal expansion and the working fluid stamping, the melted and gasified workpiece material is thrown out of the discharge channel, thus completing a spark discharge process.
When the next pulse arrives, the above spark discharge process continues to be repeated to cut the workpiece into shape. The cutting trajectory of the metal wire is controlled through CNC programming.
Wire cutting can cut many difficult-to-machine metals and alloys, including carbide, titanium, tungsten, tool steel, quenched steel, carbon steel, nickel, magnesium, molybdenum, aluminum, high-speed cobalt, etc.
Advantages Of Wire EDM
1. High precision: Wire cutting can achieve very precise cutting and can meet the processing needs of parts with very strict size and shape requirements.
2. No thermal deformation: Compared with traditional thermal processing methods, wire cutting processing does not produce thermal deformation and can maintain the original shape and size of the workpiece.
3. Wide applicability: Wire cutting can be used to process various materials, including metals, plastics, ceramics, etc., and has very wide applicability.
4. Fine processing: Wire cutting processing can achieve very fine cutting and can process fine structures and shapes.
5. Flexibility: Wire cutting processing can achieve complex cutting contours and internal and external contours, and has high processing flexibility.
6. No tool replacement required: Wire cutting does not require tool replacement and can continuously process parts of various shapes, improving production efficiency.
7. No pollution: Wire cutting processing does not produce dust, exhaust gas and other pollutants, and meets environmental protection requirements.
Hole-Drilling EDM
Long, straight, small drill holes can only be cut by EDM drilling. Straight electrodes are used to erode holes that perfectly reflect the contours of the tool. It maintains precise dimensional accuracy along the entire length of the hole. This method allows the machining of small diameter, high aspect ratio, straight holes of any depth, with diameters of 0.0015 inches or larger. EDM drilling allows blind and through holes to be drilled and can produce smooth walls or achieve difficult geometries in materials that otherwise cannot be machined. The machined surface finish of the EDM-machined holes is smooth enough to be used as a bearing surface without the need for additional machining steps.
Advantages Of Hole-Drilling EDM
Drilling electrical discharge machining can achieve high-precision machining and can process workpieces with complex shapes and small sizes.
Drilling electrical discharge machining is a non-contact machining method that does not require cutting force and can avoid deformation and residual stress on the workpiece surface.
The EDM drill pipe used in drilling is typically a low-cost, highly conductive material.
Drilling electrical discharge machining can process holes and contours of complex shapes to meet the design needs of the workpiece.
Sinking electrical discharge machining
Sinking electrical discharge machining is a processing method that uses electric sparks to generate high temperature and high pressure on the surface of the workpiece. In this processing process, spark discharge occurs between the workpiece and the electrode to generate high-temperature plasma, which causes local melting and evaporation of the workpiece surface, thereby achieving material removal and shape processing. Sinking electrical discharge machining is often used to process conductive materials,this processing method is usually used to process materials with high hardness and strong wear resistance, such as tungsten steel, cemented carbide, etc.
Advantages Of Sinking electrical discharge machining
1. It can complete the processing of complex-shaped workpieces in a short time and improve production efficiency.
2. It can achieve micron-level processing accuracy and is suitable for occasions that require high workpiece accuracy.
3. Settlement discharge machining is a non-contact machining method that can avoid wear and deformation of the workpiece surface.
4. It can process workpieces with complex shapes and make smaller and deeper holes.
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