CONVENTIONAL or RAM EDM (DIE SINKER EDM).pdf

ONVENTIONAL OR RAM EDM (DIE SINKER EDM)

Wire EDM Conventional EDM CNC Turning Milling Carbide Heading Dies & Inserts Steel Inserts / Punchse Cold Hobbing Conventional EDM is comm only known as Spark EDM . This process is often used when the desired cut or design feature does no t penetrate through the entire workpiece. Electrodes for Spark EDM are mo stly manufactured fro m graphite or copper tungsten. RAM EDM electrodes utilize a negative-formed sh ape which contains al l the detail of the final workpiece. Through CNC programm

ing, the electrode is

moved along the workpiece, never contacting the piece but creating an area between the electrode and workpiece referred to as Spark Gap. As the electrode moves along the x, y, c, and z axes, complex indentations, shapes, vents and cavities are created. The intricacy that can be achieved with conventional EDM is unmatched by any other method of machining.

Typically RAM EDM applications are performed with the workpiece fully submerged in solution bath. This fluid serves various purposes including flushing away of the eroded material, cooling the heat affected zone and preventing damage to the workpiece, and acting as a conductor between the electrode and the workpiece. Spark EDM has become a standard m ethod for machining production prototypes due to the precision and abstract cuts allowed by EDM that are not available through

alternative m achining systems. HDT electrodes are created through a 4-ax is high speed milling process . Our electrodes are milled to completion and incorporate all features of the final product with no hand-scraping required.

Benefits of RAM EDM A variety of shape s and sizes inside blind cavities Remarkable accuracy and fine finish control with no compromis e to structural integrity Shapes are burned into hardened materials eliminating the chance of s ize change caus ed by heat treating Production with greater consistency, repeatability, and efficiency Little required t ooling means reduction in set-up time Internal s plines, blind keyways, m olds Hexes for special bolts and parts & helical cut gear s and s hapes Complex shapes that would otherwise be diffic ult or impos sible to produce with convent ional cutting tools Extremely hard material machined to very close tolerances Very small work pieces where conventional cutting tools may damage the part from excess cutting tool press ure There is no direct contac t between tool and work piece. Therefore delicate sections and materials can be machined without any distort ion.

Small Hole Drill EDM (Hole Popping)

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Small hole drilling EDM machining allows a 0.3mm-6.1mm diameter hole to be drilled through a 100mm piece of soft or hardened steel in about 10 seconds with an average wear rate of 50% to 80%. T his process uses a long brass or copper electrode in the form of a tube. The electrod e is held in a chuck and rotated as a flow of distilled water flows through the electrode and flushes away the eroded material. Though small hole drilling EDM was initially used mainly for pre-drilling holes for wire EDM, its uses have since become m ore widely recognized. Mold and part manufacturinginjection nozzles, oil drain holes, hydraulic cylinders and dowel pins, as well as turbine blades, ball bearings and safety wire holes in hex nuts are just s ome of the m anufacturing areas that benefit from the use of small hole drill EDM . HDT has found that small hole drill EDM also has a place in venting,

sm all ID work as well as

workpieces with small diameters.

BENEFITS OF SMALL HOLE DRILL EDM Less time spent means shorter lead times Drilling is done into hardened materials elim inating the chance of size change caused by heat treating Little required t ooling means reduction in set-up time

SMALL HOLE DRILL EDM SPECIFICATIONS & CAPABILITIES x-axis movement 6.75” z-axis movement 10.75” Axis vertical movem ent (w-axis 8.5”

Maximum workpiece weight 440lbs Maximum workpiece dimens ions (14.5” x 15” x 10.75”)