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Electric Discharge Machines - Technology.

Trends in computer emergency power distribution.

EDM is a modern techniques have several advantages as a result of that work more and more convinced.

EDM EDM technology is still needed is the development of fungi on accurate. Molds and machine parts with complex manufacturing processes, the most active users EDM challenge to find solutions that will happen. Metal cutting industry. The ability Machinery Carbide Carbide and the highest degree of accuracy and better than intervention operators are not ready to be hoped the most. If EDM to National Socialism.

EDM Today is not an ambiguous term like a few years ago. But there are all kinds. Statement is ambiguous. . For years, researchers have a lot of study on the distribution of the finished EDM. A number of assumptions made. But it is different now. Understanding of the practice.

It is difficult, a so- complex process that often can not describe to be seen. Since some of the physical and chemical phenomena such as heat, light tone. Electromagnetic radiation, etc. As of today they are not fully understood and is not calculated. Modeling theories on the assessment of the state space can be used. But all approaches. And produces no Gaps in good condition. As the market leader in the EDM.

EDM, the process of cutting materials and supplies has been cut off tangent, Physical Gap between the two. . May this gap has created gaps in understanding. Perception EDM is still said to be art. EDMing. By the time 20 years, with new ideas. Makes predictions very

Ater the war, Russia นัก BR Lazarenko and NI Lazarenko discovery process. EDM and since then, research has continued. EDMs in the last 20 years had a 6-8 times greater.

It is very important foundation. Input / Output of EDM understand and appreciate the innovative. EDM.

INPUT.

V power supplies.

v material parts.

v power in the media.

EDM process.

v temperature.

v power.

OUTPUT.

Cutting speed v

v accuracy of the work.

v finished surface.

EDM has been separated into two different categories. Because the various ways in the performance process.

SINK EDM or a jump or EDM EDM RAM.

2 EDM.

SINK EDM.

We know that the completed work. EDM is not better than the electrical efficiency. Output as surface quality and accuracy of the total production depends mainly on the electrode material. . Is the fact that 70% of workers and 20-30% of Cost of electricity. In the 15 years to develop the wonderful quality of materials, electricity in particular. Graphite. Graphite is now used simply to import mostly abroad.

In India, we see a change from copper to graphite material power. . Choosing the right materials to the seller. Almost 15 types of materials Graphite and styles filling

Resolved, materials such as' copper or graphite, depend on the most, how effectively the size of job generation. At the conclusion of several power supply options. . In general, if you ask the user for Asia EDM, graphite, copper, and selected, as if the user from USA. In short, graphite preferred if a large electrical size, it centers more easily and faster than the computer equipment. Good quality and structure of the rice imported graphite is in India burned. Machinery is a major problem in graphite dust It is a big headache, but above all with a special vacuum cleaner equipped to handle.

Copper is the most popular material in Thailand as cheap and can be a simple machine to machine lathe. . Copper in the production of electricity. EDM is the most popular and how fast, while Graphite EDM is very slow and difficult. Avoid the most.

Of the EDM process of heat and hear a more stable power supplies has a very low copper are placed compared. Carrying heavy

Although EDM model should produce electrical energy, is not allowed to wear and easy to enter, affect the accuracy and finish. Work

It is necessary

With a wire, so many beautiful and decorative effect.

Power between the two dressing. EDM Sales of electric cars decorated.

Three changes of power between. EDM.

4th to compensate for round electric train 2D/3D Input power.

5 of the audit process control exactly EDM to reduce power consumption. These functions and strategies to achieve the correct dimensions and finish in death. Or to die.

Innovative technology. CNC also found its way into the EDM, EDM is a process of slow speed. CNC does not play a role in increasing productivity.

But it.

1. EDM model to help the couple. - Can be used in relation to the EDM.

This is called a. one ORBit cycle.

1. Process control for continuous review. EDM by a space.

Conditions and adjusts the pulse EDM.

1. Reduce electricity use by more than one split

Electrode and use change. ATC (Automatic).

1. Manual interruption, such as automatically changing the electrode tool.

Magazines and so changes in the parameters. EDM automatically.

Select code EDM predefined.

1. User interface, which allows for efficient user only.

And export performance and an automatic process.

EDMing and EDM parameters.

6th Arm machine with fuzzy logic-based control technology fine

Significantly improves the process. EDM is made.

Directly coupled AC brushless motors will be used by manufacturers to achieve less. Fast This optimization RAM speed machine. EDM in the cavity depth rapid decline of electrodes for a short period of time. The obligation to remove the waste in the EDM. Therefore, damage due to electric field. / Because the electrical arcing at the motor manufacturer. Linear to achieve higher speed RAM.

EDM EDMing a slow process. Great tool and die time. . Renames or high-speed grinder together. HSM in the computer market is dead hard disk directly

Color Theory is a hard color milling machine tools and general hardware designed and manufactured to the cycle is cut very high. (15000-40000) in most cases, this distance the plate material usually mold / Can be made with high-speed computer. Machine complex cavities by the process of EDM. This project can not unless the savings Death. / To this larger and reproduce in nature.

Both processes have, EDM and HSM. Limited, one day, and now they are admired. Jobs in India supplies store

EDM process has been refined to the flexibility and precision that have a significant impact EDMing reproduce. Put in a refined way of the need for different types of work.

WIRE EDMs.

Basic Concepts of Material Removed be, as the die-sinking EDM, wire EDM Air But by design, quite different. . For example, a wire EDM machine all. A CNC Sink - EDM can machine or not. CNC.

This machine is in India in the spring. 80th contribute the development of electronic and CNC machine to be made, Wire EDM, said that while in this increase. 6-8 times compared with the older machine.

Unlike Sink EDM, electric case. Wire EDM is a simple fixed size. Line, the complexity of the design and manufacturing of power went off

Efficient and effective machines of the most solid, depends on many followers of other factors than themselves. . These are important supplied to the machine itself. . You

1. Wire material

2. Metal components and preparation.

3. Clean water is isolated.

4. Clean and controlled environment.

1st Cable material.

Wire EDM has developed a machine to changes in technology and new applications' needs.

First, using a copper wire WEDM. Soon the brass wire existence came as a particular alloy of copper and zinc. It is true that the higher proportion of zinc, a good cutting speed and on different lines. (We are not in this Theory go. .) Also improves the performance in terms of improving the skin and the completion of specific carbide and PCD - polycrystalline diamond.

Since there is no. Company production can not be pure zinc wire drawing production. /. The process is not to draw reliable and cost-effective if the wire zinc content more than 40%. Stents with a coating come with pure zinc. 100%, but due process of coating thickness Limited Article to a few micrometers.

Galvanized wire in consumption are fast at low temperatures. Evaporation. is the use of efficient. Largely limited to 80mm thick. Distribution annealed wire thickness. 30-40 microns and heat treatment is distributed roast. Will a top speed of 45% zinc and the mass production and technology have. Electronica is the way in which wire

Researchers of technologies to improve the content. Zinc. Five years ago, Dr. Dan Tomalin discovery process called development. Gamma line break, which is 65% zinc to continue to accelerate Section allows 10-50% in many cases.

We now have the option of nearly twenty species. Wire for more productivity. . Brass Brass Brass steel distribution. cored solid brass / brass line molybdenum has a few weak in the world.

The diameter of the wire. 0.1 to 0.3 mm higher than the current density is not Pat currently has very little time is reduced. 1.5 to 2 ms, the entire current up to 500A or more will be issued regularly. . Due to the rapidly changing innovations in electronic devices such as electricity. MOSFET switch allows for a short period of time. Current church tower high number of pulses per unit at higher material removal rates is sold as a cut is given. . Mm2/min

to accelerate in the last 20 years, the cut. 30 mm2/min. 300 mm2/min. Nearly 10 times.

Metal parts.

Typically show the cut and manufacturer of all finished in class speed of solid steel as forecast Electronica speed cutting and dressing the steel surface. HcHc the brochure.

Cutting speed and accuracy of different materials due to changes in the behavior of the metal. EDMing.

Titanium.

Not very often used in India engine, but it is an important metal in industry, aviation, space, and the world. . Due its natural properties found in human body to replace the joints and dental implants.

WEDM cutting through titanium. 90% to 100% of the Speed used depends on the steel cable. Because water is conductive oxidation process, the cutting surface during cutting of the blue. Titanium.

Special anti-tumor formation root damage caused by moles circuits such effect.

Copper.

Copper is heavily used in several major industries in the jewelry industry. Coin tube and wire-EDM cut EDM electrode pulses as estimates. 80-85% of the speed tool steel.

Aluminum

This Alloy is in several. Al with a low melting temperature. Therefore, about 250-300% faster than steel and finished diluted faster speed. rougher results, while Aluminium EDMing.

Carbide.

A lot of hard material with cobalt binder are mixed and burned. Cobalt is a conductor with high-strength carbide. . We WEDming, cobalt dissolved before the loose binding Carbide makes this carbide particles and destroy the tumor by mole hair with water and electricity. Dielectric and oxidation Cha away the hard metal touch. This is a common phenomenon in all WEDM machine and is as Cobalt, announced a big loss. degraded life.

Technology Approach will be set by the manufacturer to reduce these impacts.

Clean water is isolated.

Conductive Water plays an important role in WEDM maximum Efficiency achieved.

Nature of water as insulators. : -.

You should, "said particle size. CLEAN 'is the filter should be in Micrometers are dissolved. . Paper filter cartridge or filter bed mineral is mainly

2 should be 'clean' heat. The water heats up the process. EDM and Circulating pump to run the EDM process chillers come as standard equipment to maintain temperature. dielectric machining.

3 should "chemical CLEAN 'deionization. Water during the cutting process and bring the water. Ion exchange resin mixed bed is available with automatic navigation. Application to control the recommended level.

CLEAN and Environmental Motors.

Environment, they should be stored be kept. Temperatures regularly in general prefer an environment to keep the the engine room. 20-22? C.

Changes in temperature. Cut Score -.

- Parts of the curve or twist

- Stable oil

- Strains. As the temperature is the most deteriorated section

In Thailand, since the end of the summer heat, many problems stand in relation to the accuracy. Surface

Will find that cutting speed drops. WEDM by more than 15% for higher temperatures. 10%.

WEDM and limitations of the remedy.

The bow and the slender and fix it.

WEDM machine is designed to ensure a smooth Level of need for CREATE The axis parallel to the main axis XY complement. But the process of establishing some wire EDM own. Bow / the lower the effect. Accuracies in any way for any manufacturer. Overcome these limitations by trimming or cutting of the tail cut off, or several times after the first cut. The accuracy of the low energy cut tail depends mainly on three parameters such as peak power control accuracy. Complete travel cable vibration-and water-control mechanisms. jet.

Many manufacturers have cut Innovative technology with the tail 5 of the control parameters of the three above.

Control Strategy CORNER:.

Because high-strength mechanical and electrical actions. Wire on the radio link between the cutting wire lines are probably the program path, around corners or sharp Edges with very small radius on the left corner damage. Each manufacturer has cut into - integrated fuzzy logic control strategy, innovation save the angle between the line.

Frozen machines.

In these types of Wire Machinery attempt to make the bath water. Under the conditions of the machine difficult to fill with water and cut to the plane. Extrusion die waiting soaking parts. Machine is always preferable. . Most of the producers and the exposure time machine.

Effect of heat on the metal surface. Integrity.

In the process of EDM. The surface is more concerned with phenomena that directly alter the structure of the starting material. As a result, the affected area is not included with the source material.

Defect is mainly due to processes that by the beginning The strike triggered first. EDM spark

Surface damage

• Due process

• Due the chemical processing.

• Because electrolysis and corrosion.

Damage due to thermal processes.

With the strike, the first on the surface of a metallic material sparks. Melting and crater occurs. Melt is drawn back to the crater sparks, because the surface tension.

This material on the surface refreeze cut production floor. Very different properties than the starting material. This layer is a white layer "or Recast layer.

Under the white layer is a field such as the "HAZ thermal effects known. Zone '.

This happens because the hard layer at higher temperatures. Melting temperature, but not hard surface, this layer is hard and brittle.

Damage by the effects of chemical

EDM surface by chemical impurities and electrical insulation. From the perspective of carbon impurities important. Small Effect of carbon dioxide, particularly the behavior of steel WEDM machine in chemical contamination of ion particles is more or less neutral process. Deion RAM EDM, but no such mechanism always wanted to be isolated from oil changes.

Damage from electrolysis effects.

WEDM process using a conductive water Part line is positive and the cathode voltage Space Operations cause reaction of water molecules decreased the cathode and oxidized at the positive. The parts are more or less as anode is consumed depends on the type of metals. This leads to skin aging. The parts.

Effect

Because EDM process, such as soil, white floor Stock re - strength, safety floor rather than the parent material occurs.

Today's high-speed switch for a short period Total current pulse technology to control the overall height is to reduce the impact. However, thermal properties of the process. EDM itself and could not all defects to eliminate. Thickness of the affected zone can vary up to several micrometers, depending on the rough / Skin parameters.

Cut the tail at lower power can help improve the surface

Reduced mechanical properties of metals in the affected class of tools with short life.

The perfect Surface for the dead / penetration of the surface profile of heavy metals makes it; Affect wear resistance.

New trends in EDM application.

The EDM industry.

EDM is the vertical axis in the form of operations of the decade. . increased in a few years. WEDM performance of the industry, order forms

Or molding a coffin in the old theory has not changed for years

One part is by turning on power or materials in liquid Shape or a channel display repeated first. . Channel well, and the accuracy of the completed form to a model of good size and the other part. Life form is very important for plastic parts that normally die as part of a complete

In the area of the WEDM process.

1st Current.

This was the first time in the WEDM process. Complex multi-precision electrical copper and electrons is not the same as Sian deflector What dissipate very difficult and time consuming.

2 Make Mold Base.

Bag to correct the number plate holder. Thick base mold mold base size saves big. . Place a square can be cut without corner radius be.

3 Insert Mold.

It is not without quick cuts and accumulated an average accuracy because of overlapping.

Complex geometry of gears or spline is virtually impossible to create a great machine. conventional. WireCut restrictions in pressure angle and tooth width not. Other transmission characteristics coil or coils. Gear box can use any shrinkage factor can be reduced. Easy.

4th Extrusion die.

Extrusion Nozzle plate and a large body of angles that can be easily cut by WireCut.

5 See Travel Gear.

More plastic gears is not because of the small size of the teeth. Use of wire in the 50-70 micron cut is very simple.

6 Place

Connector Insert Mildew resistant to many duplications, it is very close. Labor intensive and very expensive to collect all this ground and avoid. WEDM.

7 core pin and pin hole blown up.

Wire EDM can be used effectively to reduce all through the hole in the slot after hard. Holes fit the size and sharp edges of the box dead. Make it clear to the possibility

8th Reduce or eliminate conflict.

Polished blocks in Thailand is labor intensive. Work hard and could have been avoided by EDM wire, which are now down to disposal. 1 μ finish Rmax.

Micro Machines. EDM.

MEMS technology is of fundamental importance in the production of small parts and components.

Until recently the focus has been produced. Microelectronic components and productivity of the limited technology. Other. Now needs a majority of the developers of the micro-micro-machine. Machine tool technology very popular will be.

Micro - Processing is a general term for very small sub-millimeter by millimeter size microcapsule, such as robots. Inserted in the human body for medical treatment, small vehicles as sensors. Micro Machine Micro Machine has the advantages of three-dimensional shape of machinery problems.

Last year, the demand for technology equipment has been increased. Micro broad range of industries including

• Aerospace.

• Medical

• Automotive industry.

Micro Technic machine parts, even less as something more than 100 microns thick Hair. - Hair 75 microns.

For example, technical equipment used in the production of small parts, such as

• Medical Device

• Micro-module.

• Electronic devices.

• Valves Micro.

• Tools for IC's.

• District Small - stimulus and motor.

Productivity and equipment

Today the shop is committed to Working conditions to achieve higher productivity and output.

Automation can solve problems automatically. But not for the benefit of the automatic work. If a lot of time wasters that can reduce the chances for competition.

Generally EDM Job Shop, the majority work in four specific steps.

1. Preparation program and part of a

2. Job Preferences / Compliance. / Download / transportation.

3. Cutting.

4. Audit work.

We depend WEDM machine to run on many factors. People want to downplay how -.

1. Screw Wire spool / Change

2. Interrupted power.

3. Replace equipment.

Top the specific production cut tax revenues.

Although the others. All other calls are important in order to save it. One can imagine the time-eater reduced.

Let us view this from the perspective of "Lean. Job Shop" that the automated system means to enhance productivity. Lean Manufacturing is required, an abbreviation for waste disposal. Simple procedure and can accelerate the production of such concepts.

Modern manufacturers. WEDM and Equipment manufacturers to continue to be Used to support users in different ways and accessories to minimize human intervention reduced. Waste of energy Curb cut time and the time available for improvement. . be reviewed.

1. Job preparation and programming. : It is a strategy of Cutting edge work such as pinholes start, rough. / Cut tail to other manufacturers. Mobile Technology recipes and instructions for the process without interference, so you save time.

2. Tools: sufficient time can be saved. Mechanics with today.

• Good quality.

• Inexpensive.

Applications and services.

• Single minute exchange of die (SMED).

• Open Single Clamp of the dead.

• And with a single command line operation of the machine.

This reduces unproductive time on the computer.

A cutting process: cutting full-time by choosing the appropriate cutting speed and cutting several strategies to improve.

While offering a maximum cutting speed. But top speed. How do I create defects, degeneration of the highest accuracy and the job to end. . The time is bad for the reduction. defects.User speed of decision making is appropriate, the average maximum cutting speed than to maximize efficiency and cut.

Second audit work: modern equipment capable of delivering consistent quality in regard to the accuracy and completeness of the factor approach. / Will count in the previous section. The time can save a lot of work inspection by a small check. Size

The time lost by the intervention.

A spiral wire.

Material errors may misuse parameter cut lead wire breakage

Cable guide screw to eat at least. 5 minutes if you are in front of the machine. This can save time by using the. Automatic Wire Threading location

This feature is in Most WIRE EDMs.

Auto wire threading usually have time. 45 seconds, which is to save more in terms of time.

In the case of death on the field with several lines. AWT will automatically cut and threaded programs do not have the performance is finished in force.

Two lines loaded spool / spring

Change wire tube is disrupted in the event at a large cut above. 24 kg to 45 kg high coil may take several days and the time will change until the lights often to reduce.

equipment manufacturers to offer an added value. To reduce human intervention.

3 Power interrupted.

In the Indian state Failures often have the power.

Many shop owners have created a series of backup power supply. But few places have built-in car conversion conversion generator Manual time-consuming and depends on operator attention. This time of 5 minutes to 15 minutes.

Generator set has changed. Car over the place to start. 1 minutes

With electric automatic. Place to start cutting the turnaround within a minute.

4 Changing Consumption: Manufacturer provides information on the life of consumables such as the currently recommended pickups resin wire, filters, etc.

Amending standards to save you time supplies

Automation.

Now days, are installed mainly in the developed tools. loader unloader / working robot load / transport the machine so disappointed

Improved Performance in High-speed cutting with precision and surface quality of the job tolerable. Wire EDMs popular not only in the room. But also tools for the production, which does not save. A few years ago.

Finally, innovation in EDMs are to reduce the complexity of the work. EDMing of economic Instruments, so long as the competition mechanism. Or molding, aerospace, pharmaceutical and other industries such as

About the Author

CEO Electronica Machine Tools Ltd., Pune, India

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