EDM New electrode idea improves die-sinking EDM

Writer /
Eckart Uhlmann, Cora-Sophia Wolf and Jan Streckenbach
/ Steffen Donath

Device and mould-making is a key consider industrial manufacturing. Along with machining processes, spark erosion can be used, the electrodes of that are very advanced to fabricate. Researchers are actually growing an easier methodology for this.

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An innovative electrode concept developed at the IWF relies on segmented single electrodes. Round structures can thus also be produced, as can be seen here.
An modern electrode idea developed on the IWF depends on segmented single electrodes. Spherical buildings can thus even be produced, as may be seen right here.

(Supply: IWF)

In Germany, device and mould-making is among the most essential branches of the trade. In an effort to stay internationally aggressive, German device and die-makers are striving to beat the manufactory-like particular person manufacturing and obtain industrial effectivity and excellence. Profitable toolmakers, due to this fact, try for modern device ideas.

Even when a number of geometries may be mixed on one electrode, typically quite a lot of 100 ≤ n ≤ 1000 geometric-specific sink electrodes are required, that are manufactured and successively spark-eroded with a view to receive the ultimate contour of an injection mould. This ends in the drawback that the manufacture and substitute of the sink electrodes usually account for a a lot bigger proportion of the full manufacturing time than the precise sink erosion course of. In an effort to scale back the electrode manufacturing time (tF) and the machine set-up time (tR) in addition to realise the potential for inside flushing throughout electrical discharge machining, there are analysis approaches to bundle tubular electrodes as particular person device electrode segments. The shaping of the outer geometry is carried out with out machining processes. Beforehand, the general profile was adjusted both exterior the machine system or by utilizing moreover manufactured forming instruments. The truth that bundled device electrodes are appropriate for spark erosion countersinking was efficiently demonstrated by comparisons with milled countersink electrodes.

On the premise of present necessities for a device idea that allows extremely versatile shaping, using very onerous device electrode supplies and focused flushing of the frontal working hole (sF), an modern device idea for roughing machining in spark erosion countersinking has been derived. This idea is predicated on the bundling of partially chamfered sq. rods as particular person device electrode segments. By actuating every particular person phase, a fancy 3D kind electrode may be set for spark erosion countersinking. This actuated and variable device electrode allows spark erosion countersinking of various advanced geometries with one and the identical device electrode in order that using machining processes for shaping may be distributed with.

The quick, actuator-based setting of the shape electrode, for instance, on the premise of CAD information, additionally allows integration into automated course of chains. Geometrically easy particular person device electrode segments additionally supply the potential to make use of difficult-to-machine supplies, corresponding to carbide, as device electrode supplies. This will increase imaging accuracy and course of stability and reduces processing time.


The investigations had been carried out on the “Genius 1000 The Dice” machine system from Zimmer & Kreim in Brensbach. A pyramid profile was ready in three particular person phases with a respective countersink depth of tSenk = 2 mm with the device electrode surfaces AE1 = 25 mm × 25 mm for the first cavity, AE2 = 15 mm × 15 mm for the 2nd cavity and AE3 = 5 mm × 5 mm for the third cavity. Utilizing the method parameters of VDI stage 44 ([11]) to attain arithmetic imply roughness worth Ra ≈ 18 μm, the profile was sunk into a chrome steel workpiece of kind 1.4301 by spark erosion.

For statistical functions, every check was carried out in triplicate. For investigations of the variable device electrode with inside flushing, a chamfer was additionally hooked up to chose device electrode nook segments and a flushing connection built-in. The dielectric was directed to the efficient level through the chamfers, which served as rinsing channels.

It may be seen that the identical elimination price of V W,i could possibly be achieved for all three cavities utilizing un-chamfered particular person device electrode segments with out inside flushing as for the countersunk electrodes manufactured from stable materials. Utilizing chamfered particular person device electrode segments with inside flushing, the full elimination price of V˙W,ges. is 13 % decrease than for the countersunk electrodes manufactured from stable materials.

The decreased elimination price of the primary cavity (V˙W,1) may be defined by way of inside flushing with a flat countersink depth (tSenk). Course of-improving results may solely be noticed with the deeper third cavity. Right here, the rise within the elimination price of V˙W,3 may be defined by the focused flushing of the lively website.

The lateral working gaps (sL) had been lowest for chamfered particular person mould electrode segments with inside flushing for all three cavities. Nevertheless, the dispersion (σ) was better than with using countersunk electrodes manufactured from stable materials.

The decision may be elevated by decreasing the dimensions of the person device electrode segments in order that even advanced geometries may be imaged. Rotationally symmetrical cavities may be produced by rotating the Z axis.

It was depicted that the bundling of particular person device electrode segments reveals solely minor deviations in comparison with the outcomes with a countersunk electrode manufactured from stable materials. The benefit ensuing from the saved milling occasions (tFräs) and set-up occasions (tR) outweighs the drawback of the process-related scattering (σ) that also exists.

The benefits of inside flushing in spark erosion countersinking may be decided by focused technological investigations. The method-enhancing impact grew to become obvious with deeper cavities.

Sooner or later, publicly funded tasks will embrace the updating and downscaling of particular person device electrode segments, know-how optimization to extend course of reproducibility, optimization of rinsing situations and using difficult-to-machine device supplies.


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