Edm electrode materials selection guide engineering360. Edm electrodes include components made from brass, copper and copper alloys, graphite, molybdenum, silver, and tungsten. Carefully designed partial area electrodes made of premium materials can provide troublefree, unattended performance. A brief explanation about the design principle is presented in this paper as well as comparison of experimental machining results between uniform tool offset and the said method. An overview of technology and research in electrode design and. This is an important design consideration in designing the tool. Edm is an acronym for electric discharge machining, a process that uses a controlled electrical spark to erode metal. Aug 25, 2010 when the edm machine used is only capable of 2d orbiting rather than 3d. Present work rotary brass lead electrode was used to machine tungsten carbide work piece material.
In 1974, poco published the edm technical manual, the first document in the field based on laboratory testing of edm electrode materials. Introduction designing an electrode for electrical discharge machining is a bachelors degree thesis, primarily focusing on the step by step process of explaining the design process of an electrode for an edm machine. Filtration systems for wire, sinkers, and small hole edms. Edm electrodes consist of highly conductive andor arc erosionresistant materials such as graphite or copper. Electrode design also affects on the cost of electrode. When a blind cavity is required, a formed electrode is machined to the desired shape. Pdf electrical discharge machining edm is one of the nontraditional. Thus, there is still room for improvement in the edm electrode design. All production is carried out on site utilizing our stateoftheart 4. A computeraided edm electrode design system for mold. Dont read this if you use graphite electrodes for edm. Find edm electrode materials on globalspec by specifications. How to convert pdf to word without software duration. So knowing about electrodes is important in doing ram edm.
Combining powershape for design, powermill for machining and powerinspect for inspection, autodesk electrode helps reduce learning times and support costs, whilst helping you. In such repetitive, automated situations, maximum productivity with minimum operator intervention is the key. This thesis is about designing an electrode for an electric discharge machine. Electrical discharge machining edm is a metal cutting process that uses electricity to burn away small bits of material until the desired dimensions are achieved. Daco can design and machine edm electrodes to almost any shape or style using the latest solid works design software, and can machine all electrodes inhouse on their high speed cnc graphitecarbon cutting machine. Developments promise to streamline situations where edming is unavoidable, as well as make edm attractive as the most efficient machining process in many cases where complex mold shapes are involved. With wire edm there is a constant supply of new wire, or electode material. In edm, a potential difference is applied between the tool and work piece. How ram edm works ram edm uses spark erosion to remove metal. Many edm electrode design steps are being automated, making electrode production faster and easier. Electrical discharge machining is a machining method primarily used for hard metals or those that would be very difficult to machine with traditional techniques. Even though edm copper still has a huge market in europe and asia, the use of edm graphite is gaining momentum there as well.
Our graphite electrodes can be preconfigured for use with your standard connections, for fast and easy fitting on your machines. Electrical discharge machining edm makes it possible to work with metal for which traditional machining techniques are ineffective. Autodesk has developed an integrated design, manufacturing and inspection suite for faster, more reliable production of copper or graphite electrodes for edm. Pdf electrical discharge machining edm is one of the earliest nontraditional machining processes, based on thermoelectric energy. Electrode design with 2d orbit in mind solidworks forums. This electrode is then carefully plunged into the workpiece, causing sparking over its surface as features close the sparking gapthe distance.
Copper electrode design in nx 12 for edm for more queries drop your message and comments. Edm, electrode shape configuration, taguchi method, doe, parameter analysis. A small gap between the electrode and the workpiece allows a flow of dielectric oil. The design of edm electrodes for mould inserts is a very important process in the design and manufacture of plastic injection moulds. Tool electrode design details design type, name, symbols, and. The production of electrical discharge machining electrodes using. Then, by means of electrical current, the formed electrode that is surrounded by dielectric oil reproduces its shape in the workpiece. Generally speaking, however, the principle characteristics of electrical discharge machining should give you a sense of whether edm is a good fit for your application.
However, the electrode design is very time consuming. This algorithm is integrated and developed in commercial cad system as an intelligent tool to automate the electrode design process. The objective of the present work is to optimize the machining parameter i. Edm typically works with materials that are electrically conductive, although methods have also been proposed for using edm to machine insulating ceramics. For example, edm is typically slower than other machining methods, but it also tends to be more predictable, accurate and repeatable. Estimation of mrr for edm machining of tungsten carbide using. Electrical discharge machining edm design consideration. Reference systems for electrode manufacture and diesinking. In diesinking edm, the electrode is moved only in the zaxis direction, while in oscillating edm, electrodes are oscillated in both the xaxis and yaxis directions to realize high accuracy machining.
Edm, process parameters, mrr, electrode design, manufacturing. Edm electrode design drawings of electrode byoungjin kim. Nx electrode design software delivers a stateoftheart solution to enable todays tool manufacturers to shrink their lead times and reduce their costs. The thesis will guide the reader to understanding the use. The patented and compact macrojunior system is intended mainly for small electrodes. Electrode design for edmeasy waynx unigraphichindi. Researchers have explored a number of ways to improve electrode design. I will also show you that how you can make design of electrode in nx unigraphic. Polarity, rotational speed of electrode, peak current, pulse on time for getting higher material removal rate 2. Cad, design, electrode, edm, orbiting introduction.
Electrode selection and machining are important factors in operating ram edm. Apr 15, 2000 many edm electrode design steps are being automated, making electrode production faster and easier. The electrodes are available in graphite, copper, and copper tungsten which material is most suitable varies per application. Engineers have fully integrated edm into the design process. In this video i will introduce that what is edm electrode and why electrode is used for critical machining. Automation in the design of edm electrodes sciencedirect. The electrode design software application in nx streamlines electrode modeling and design for any tool project that requires electrical discharge machining edm. There are various kinds of emd, like, wire edm, electrode edm. In cnc edm operation, flushing may be the primary consideration in electrode design. Nx electrode design software provides a timesaving, stepbystep solution that automates the entire edm process from design through production. Novotec offers a large range of threading electrodes from stock. This paper presents a systematic methodology which includes uncut detection in the injection mold and automation of edm electrode design. Fifteen years of experience and certification to standards iso 9001 and 14001 have made our company into a market leader, providing an innovative service model in the field of edm.
By combining industry knowledge and best practices with process automation, nx electrode design streamlines electrode modeling and design for any tool project that requires edm. Unlike other macro systems, in macrojunior the chuck, not the electrode holder, has positioning tongues. Our technical office is at your complete disposal to meet any request, including electrode design and dimensioning for specific applications. This paper introduces a computeraided electrode design system for. Small hole edm drilling small hole edm drilling, also known as fast hole edm drilling, hole popper, and start hole edm drilling, uses a guided hollow electrode to drill holes by means of electrical discharge machining by eroding material from the workpiece, as shown in figure 1.
When determining the best edm electrode material to use, the debate between graphite and copper has been long standing and is yet to be resolved. A detail explanation about electrode design steps and its validation is presented in the paper. Edm is an acronym for electrical discharge machining, a process that uses a controlled electrical spark to erode metal. With the highest quality manufacturing standards, graphel carbon products electrodes are carefully crafted to meet your most demanding needs. Edm electrode design side setting block byoungjin kim. Electrical discharge machining, edm is one of the most accurate manufacturing processes available for creating complex or simple shapes and geometries within parts and assemblies. This paper introduces a computeraided electrode design system for plastic injection mold manufacturing. Also, edm grinding, when the electrode tool design as a rotating disk 145.
Complete graphite and electrode machining facility. This paper presents a systematic methodology which includes uncut detection. Dont read this if you use graphite electrodes for edm in electrical discharge machining, graphite electrodes are the most popular for making the complicated components in injection mold making. A new approach for uncut detection and automatic design of. Edm electrode design drawings of electrode youtube. Designing an electrode for edm 2014 bishwas shrestha page 7 1. Improving the performance of edm through reliefangled. A large number of edm electrodes are used in plastic injection mold manufacturing. There are many ways of designing electrodes for oscillating edm. This way i wont be violating any agreement and the cad models will be available for study in educational purposes. Any radii that are not vertical on the electrode, and any steep draft angles, will not be produced at the correct size.
Ram and mohan rao 4 conducted an overview of technology and research in electrode designand manufacturing in sinking electrical discharge machining. Electrode design takes up a substantial amount of time in the design process, and it has important implications for the quality of the mould product and the efficiency of the mould manufacturing procedure. Many argue that graphite is the preferred electrode material while others stand firm with their preference for copper. It only works except by specific design with materials that are electrically conductive. This includes level of detail, material strength, wear resistance, surface finish and cost. An algorithm to detect sharp corner uncut for electrode design is introduced in the paper.
Many other exciting things have happened in the years since the first appearance of the edm technical manual. International machine tool design and research conference, birmingham. Its power supply generates electrical impulses between the workpiece and the electrode. Since there was quite a lot of interest in edm electrodes i have decided to do the following thing. This work presents an experimental work in orbiting edm which design of the electrode used adopt the nonuniform offset method formulated by the authors. Srl is specialized in the design and production of electrodes in graphite, copper and tungsten copper. Pdf an overview of technology and research in electrode design.
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