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Spark erosion process plays an important role in modern manufacturing, especially in handling hard and complex materials. Spark erosion process (EDM) includes sinker EDM process and EDM wire cut process , each with its unique advantages and application scenarios. This article will discuss the principles, characteristics, and applications of these two spark erosion processes in different fields.
Sinker EDM process is a technique that processes the desired shape inside the workpiece through an electrode. In this process, the electrode itself is made into the shape needed by the workpiece. The sink cutting method of the spark erosion process includes the following steps:
Sink cutting equipment consists of a machine tool, an electric device, and a container. The machine tool is equipped with oil feed and position control systems, the electric device generates 20-150V DC pulse voltage, and the container is equipped with a pump, filter, and flushing medium device. The feed motion during the cutting process is controlled by a numerical control system to ensure high-precision processing.
Sinker EDM process begins when the electrode gradually approaches the workpiece, forming a spark gap. Under the action of the electric field, ions and material particles gather at the narrowest spark gap, producing an arc. The temperature of the discharge channel can reach up to 12000°C, enough to melt and vaporize the material particles. Each spark leaves a small crater on the workpiece, and the final shape of the workpiece is formed through numerous craters.
Sinker EDM process's advantages include the ability to process hardened steel and hard alloy materials, and it is suitable for workpieces with small corner radii and high dimensional accuracy requirements.
Wire EDM is a method of cutting the workpiece using a continuously running thin metal wire (electrode wire). Spark erosion process (EDM) wire cutting method is mainly applicable to the following aspects:
The wire cutting equipment uses a thin metal wire as the electrode, generating spark discharge on the workpiece through a pulse current, thus cutting the material. Unlike the sink cutting method, the wire cutting method requires specific machine tool structures to ensure stable operation of the electrode wire and accurate cutting of the workpiece.
In the electrical discharge cutting process, the gap between the electrode wire and the workpiece generates spark discharge through the current, thereby achieving cutting. The wire cutting method is especially suitable for processing fine contours and complex geometries, allowing high-precision machining. It can handle a variety of conductive materials, including high-hardness alloys and tool steels.
The advantages of the electrical discharge cutting method include the ability to process complex geometries and tiny holes, with high precision and good surface finish.
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