During EDM, the tool electrode and the workpiece are respectively connected to the two poles of the pulse power supply, and immersed in the working fluid, or the working fluid is filled into the discharge gap. The tool electrode is controlled to feed to the workpiece through the gap automatic control system. When the gap between the two electrodes reaches a certain distance, the pulse voltage applied to the two electrodes will break down the working fluid and generate spark discharge. A large amount of heat energy is concentrated instantaneously in the tiny channel of discharge, the temperature can be as high as 10,000 degrees Celsius, and the pressure also changes sharply, so that a small amount of metal material on the working surface immediately melts and gasifies, and splashes into the working fluid in an explosive manner In the process, it condenses rapidly to form solid metal particles, which are taken away by the working fluid.
At this time, a tiny pit trace is left on the surface of the workpiece, the discharge pauses for a short time, and the working fluid between the two electrodes returns to the insulating state. Immediately afterwards, the next pulse voltage breaks down at another point where the two electrodes are relatively close to each other, generating spark discharge, and repeating the above process. In this way, although the amount of metal removed by each pulse discharge is very small, because there are tens of thousands of pulse discharges per second, more metal can be removed, which has a certain productivity. Under the condition of maintaining a constant discharge gap between the tool electrode and the workpiece, while removing the metal of the workpiece, the tool electrode is continuously fed to the workpiece, and finally the shape corresponding to the shape of the tool electrode is processed. Therefore, as long as the shape of the tool electrode and the relative motion between the tool electrode and the workpiece are changed, various complex profiles can be processed.
Tool electrodes are usually made of electro-corrosion-resistant materials with good conductivity, high melting point and easy processing, such as copper, graphite, copper-tungsten alloy and molybdenum. During the machining process, the tool electrode also has loss, but it is less than the erosion amount of the workpiece metal, and even close to no loss. As the discharge medium, the working fluid also plays the role of cooling and chip removal during the machining process. Commonly used working fluids are media with low viscosity, high flash point and stable performance, such as kerosene, deionized water and emulsion. EDM mainly includes two process methods of electric discharge forming and electric discharge wire cutting.
|Aluminum||Stainless steel||Mild, Alloy, Tool & Spring steel||Other metal|
|6061||304||Mild steel 1018||Brass C360|
|7075||316/316L||Mild steel 1045||Copper|
|5052||303||Mild steel A36||Titanium Gr5 (TC4)|
|2A12||430||Alloy steel 4140|
|201||Alloy steel 4340|
|Alloy steel 1215|
|Tool steel D2|
|Tool steel A2|
|Tool steel D1|
|Tool steel A3|
|Tool steel S7|
|Tool steel H13|
|ABS Flame Retardant||PEEK|
CNC machining is a modern manufacturing technique that utilizes programmable software and computer-controlled equipment to create complex parts and products from a wide range of materials such as metal, plastics, and wood.
With CNC (Computer Numerical Control) technology, the manufacturing process is highly automated and precise. The process begins with a CAD (Computer-Aided Design) file, which is converted into a set of instructions in the form of G-code. This code is then sent to a CNC machine, which follows step-by-step instructions to produce the desired part or product.
CNC machining has revolutionized the manufacturing industry by increasing productivity, improving accuracy, reducing waste, and allowing for complex shapes and designs to be produced with high precision. It is used in a variety of industries, including aerospace, automotive, electronics, and medical devices.
The benefits of using CNC machines are:
1. Enhanced precision: CNC machines can produce highly precise and accurate parts with tolerances as low as 0.0002 inches, which is not possible manually.
2. Increased speed: CNC machines are automated and can run 24/7, thereby offering faster production time for large volumes of parts.
3. Consistency: Unlike manual production, CNC machines produce parts that are identical in terms of size, shape, and quality consistently.
4. Reduced labor costs: CNC machines require less manual labor and supervision, which saves labor costs and improves overall efficiency.
5. Flexibility: CNC machines can be reprogrammed easily to create different parts without the need for complex tool changes.
6. Ability to work with a wide range of materials: CNC machines can work with a variety of materials, including metals, plastics, wood, and composites.
7. Improved safety: CNC machines can run automatically, which reduces the risk of injury for workers and provides a safer work environment.
8. Reduced waste: The precision offered by CNC machines reduces the material waste and scraps generated during the production process.
CNC machines can work with a wide range of materials including metals, plastics, wood, composites, ceramics and more. The types of materials that CNC machines can work with depend on the specific capabilities of the machine, the tooling options available, and the type of work being performed. Here are some examples of materials that can be used with CNC machines:
1. Metals: CNC machines can work with a variety of metals, including steel, aluminum, brass, titanium, copper, and more.
2. Plastics: CNC machines can work with various types of plastics such as polycarbonate, acrylic, nylon, ABS, PVC, and more.
3. Wood: CNC machines also perform operations on hardwood, softwood, plywood, and MDF board.
4. Composites: CNC machines can work with glass and carbon fiber composites, Kevlar, and other composite materials.
5. Ceramics: Machinable ceramics can also be used with CNC machines like porcelain, alumina, zirconia and other materials.
It's important to note that different CNC machines will have specific requirements for the materials that can be used. The feed rate, chip load, and spindle speed will vary depending on the material, so it's essential to understand the material properties and choose the appropriate tools and settings for each job.
CNC turning and CNC milling are both processes used in CNC machining, but there are some significant differences between the two.
1. Operation: In CNC turning, a stationary cutting tool is used to remove material from a rotating workpiece, whereas in CNC milling, the cutting tools rotate and move across the stationary workpiece.
2. Geometry: CNC turning is more suitable for creating cylindrical shapes such as bolts, nuts, pipes, and shafts. CNC milling is better suited for more complex geometries such as pockets, slots, and complex shapes.
3. Tooling: Turning tools are generally simpler and more robust, while milling tools are more complex and can have more cutting edges.
4. Materials: CNC turning machines are mostly used for turning materials such as round bars, billets, and blocks, while CNC milling machines are used for a wide range of materials such as metals, plastics, wood, and composites.
5. Speed: In general, CNC turning is faster than CNC milling, as the tools are shorter and the process is simpler.
6. Cost: CNC turning is usually less expensive than CNC milling, as the tools are simpler and less expensive.
In summary, CNC turning is best suited for creating simple cylindrical shapes, while CNC milling is better suited for creating more complex geometries. Both processes have their advantages, and the choice between them will depend on the specific requirements of each job.
The maximum size of parts that can be machined with CNC machines depends on the size and capacity of the machine being used. CNC machines come in various sizes, and they have different work envelopes that dictate the maximum size of parts they can handle.
Small CNC machines are ideal for small and intricate parts, while larger machines are used for bigger parts. Generally, the maximum size of parts that can be machined on a CNC machine ranges from a few centimeters to several meters.
For example, a small benchtop CNC milling machine may have a work envelope of around 300mm x 300mm x 200mm, while a larger vertical machining center may have a work envelope of 2000mm x 1000mm x 1000mm. In comparison, large gantry-style CNC machines used in the aerospace industry have a work envelope of over 30 meters in length.
It's essential to consider the size and weight of the parts being machined and the capabilities of the CNC machine when selecting a machine for a specific job.