EDM Technical Article...EDM also has the ability to cut very hard metals with impunity that are...

CompassPrecision,LLC

4600WestinghouseBLVD.•Charlotte,NC28273•Phone704-504-3330www.compassprecision.com

EDMTechnicalArticleByPaulLutz,KeithFelts&PatrickReynoldsAtonepointaninfrequentmachiningmethod,EDMhasgrowninpopularityoverthelasthalfcenturytobecomeanimportantaspectinthesuccessofAdvancedMachining&Tooling,LLC.Unlikeothertypesofmachining,EDMcreatesadesiredshapebyusinganelectricaldischargeorsparks.Thismethodcancreateintricatecontoursandcavitiesthatareusuallydifficulttomake.EDMalsohastheabilitytocutveryhardmetalswithimpunitythatarechallengingtomachinewithotherprocesses.TherearethreebasictypesofEDMprocesses--sinkerEDM,wireEDMandsmall-holeEDMdrilling.Allthreeworksimilarlywithsparkerosioncreatingthedesiredshape.ThemostconventionalofthethreetypesofEDMprocessesissinkerEDM,whichisalsowidelyknownasram,cavityorconventionalEDM.Inthisprocess,sparksfromasinkerelectrodethat’sbeenpreviouslymachinedintoanexactimageofthecovetedshapecausethemetaltoerodefromtheworkpieceinordertocreatethedesiredpart.Thetwoelectrodesnevertouch,asadielectricliquid,whichcontinuouslycirculatesaroundthetwoelectrodesandflushesawaythescrap,separatesthem.

CompassPrecision,LLC4600WestinghouseBLVD.•Charlotte,NC28273•Phone704-504-3330

www.compassprecision.com

WireEDMiscomparable,butasthenameoftheprocesswouldindicate,awireisusedtoprovideoneoftheelectrodes.Sparksfromthewirejumptotheworkpieceanderodemetaltocreatethedesiredpart.Thisprocesstypicallyoccursindeionizedwater.Insmall-holeEDM,brassorcoppertubesarerotatedwhileloweredintothematerial.Again,thetubenevermakescontactwiththeworkpiece,butthesparksfromthetubeerodethemetaltocreatethedesiredpart.AdvancedMachiningspecializesinthefirsttwotypesofEDMprocesses--sinkerandwire.Intotal,EDMprocessingaccountsforasignificantpercentageofthecompany’ssalesonayearlybasis.AdvancednowhasfiveAgieCharmillesEDMunits,manufacturedbyGFMachiningSolutions,tosupportthispartofitsbusiness,anditcontinuestogrowinthisarea.Latein2019,thecompanyacquiredanadditionalsinkerEDMmachine,andearlyin2020,itaddedanotherwireEDMunit.ThesefivemachinesarepartofalargefamilyofCNCmachinesdeployedonadailybasisatAdvanced.Thecompanyalsopossessessix3,4,and5-axisverticalmachiningcentersandtwoturningcenters,onewithlivetoolingformulti-taskingmillingandturning.ThesecapabilitiesarecontinuingtohelpAdvancedgrowintheCNCmachiningindustry.PerformingthewireandsinkerEDMprocessespermitsAdvancedtocreatesometrulyuniqueparts.SomeofthemorerareshapesAdvancedMachiningconstructsonaday-to-daybasisaremachinedfrommaterialssuchasInconel,tungsten,titanium,rheniumandindium.Again,thosemetalsaredifficulttomachinewithotherprocesses.

CompassPrecision,LLC4600WestinghouseBLVD.•Charlotte,NC28273•Phone704-504-3330

www.compassprecision.com

Additionally,EDMmethodsallowAdvancedtobeextremelyaccurateandefficient,keepingcoststoaminimumandcustomerspleased.TheshapesandpartsAdvancedcreateshavebecomeextremelyimportanttoitsaerospace&defense,telecommunicationsandmedicalcustomers.AbouttheAuthors

PaulLutz

KeithFelts

PatrickReynolds

PaulservesasAdvancedMachining’sEDM&MaintenanceSpecialistandhasextensiveexpertiseinwireEDM.Hegainedthisknowledgeworking16yearsforGFMachiningSolutions,aleadingmanufacturerofwireEDMequipment,beforejoiningAdvancedMachiningin2014.

Keithco-foundedAdvancedMachiningin1985andhasservedasPresidentsincethen.Heisaleadingexpertinelectricaldischargemachining,particularlysinkerEDM.HepreviouslyworkedasanapplicationengineerforAgieCharmilles,atopmanufacturerofEDMequipmentbasedinSwitzerland.

PatrickisAdvancedMachining’sOperationsManager.Hehasadiversebackgroundinvariousmachiningtechnologies,includinghorizontalandverticalmillingaswellaswireandsinkerEDM.HepreviouslyworkedatseveralothermachineshopsinpositionsofincreasingresponsibilitybeforestartingatAdvancedin2015.