EDM Machining For Sinker and WEDM

The modern mould/die making tool shop relies heavily on EDM machining, both with the sinker and WEDM. It would be almost impossible to imagine competing in this highly technical field without using a comprehensive and integrated approach. This has also changed the nature of EDM Jobs.

This approach is much different than the way things were done only a few years ago. In this not-so-distant past, there were only manual EDM machines, usually an Eltee Pulsitron and the operator used a combination of black magic and science to achieve some pretty impressive results.

All you needed, back in the day, was a Bridgeport type vertical milling machine, a manual surface grinder, such as a Harig or Brown and Sharpe, and an engine lathe. The lathe was not really even that critical, it need not be a precision one, such as a Hardinge.

All this changed when the CNC EDM was developed. Soon, every tool and die shop had at least one of these new machines. Along with this came the developMent of precision tooling, such as System 3R and later Erowa. The automatic tool changer could be filled with copper or graphite electrodes and the machine could run for days, unattended.

Charmilles and Agie were early pioneers in EDM machining, and the developed many innovative electronic circuitry technologies that made the process more predictable and controlled. The black magic aspect began to vanish.

The Japanese became major contributors to this advancing process and soon companies such as Sodick, Mitsubishi, Hitachi, and Makino were pushing the process even further along.

The high speed milling machine also totally changed the way electrodes were manufactured. Instead of a mold maker spending hours performing complicated setups on the surface grinder or Bridgeport, the electrodes are made in minutes, more accurately as well.

These mills require some very advanced carbide end mills and insert cutters to do their Job. These ball end mills and bull nosed cutters can be coated with a huge variety of coatings, such as TiN, TiCN and TiAIN.

The influence of lean manufacturing began to affect companies as well, and soon there developed work cells. The EDM machining process is now done in a work cell that includes some very sophisticated machine tools.

The cell typically includes the sinker EDM, a wire EDM machine, a CMM, a high speed machining center, a manual surface grinder and an inspection area. There are many EDM Supplies that must be included as well, such as the Poco graphite, tellurium copper, Filters, industrial dust collection systems, dielectric fluid, and WEDM wire.

The wire EDM is a truly remarkable machine. It has completely transformed the way injection molds and precision metal stamping dies are designed and manufactured. By using CAD/CAM programs, such as Cimatron and GibbsCam Wire-EDM, operators are able to produce precision components that were only a dream in the past.

The various machines in the cell are all connected by the software programs, with the electrodes and workpieces being controlled by a pallet changer. The System 3R WorkPartner, and Makino's Track Pallet Magazine (TPM) are examples of the pallet changers that used to integrate the cell.

You could include the micro welder, or laser welder in this cell, but that means somebody is making mistakes! Mold repAir is, nevertheless, very important.

hardinge lathe

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