2008 Mitsubishi FA10 Advanced EDM Wire 8071272
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X-Axis Travel 13.8", Y-Axis Travel 9.8", Z-Axis Travel 8.7", Control Mitsubishi CNC, U/V Axis Travel 1.3" x 1.3", Max Workpiece Weight 1,100 Lbs, FEATURES: Auto Wire Threading
How Electrical Discharge Machining Works
The basic electrical discharge machining process is really quite simple. An electrical discharge (spark) is created between two electrodes (solid electric conductors). The tool electrode is typically referred to as the electrode, and the workpiece electrode as the workpiece. The spark is visible evidence of the flow of electricity. This electric spark produces intense heat with temperatures reaching 8000 to 12000 degrees Celsius, melting/vaporizing almost any conductive material. These rapid, repeated electrical current discharges take place in a very small gap between the two electrodes, which never come in contact with each other. The spark gap (aka discharge gap, electrode gap) is maintained by adaptive machine controls to ensure a constant, stable distance as the electric discharge occurs up to millions of times per second.
The spark is very precisely controlled and localized so it only affects the surface of the material. The EDM process usually does not affect the heat treat below the surface. Both the tool and workpiece are submerged in dielectric (not conductive) fluid, typically deionized water.
The spark always takes place in the dielectric fluid. The conductivity of the deionized water is carefully controlled, creating an ideal environment for the EDM process. The deionized water also provides cooling during the machining process, and flushes away the tiny eroded metal particles.
Electrical discharge machining is considered a non-traditional machining method because it uses electric discharge to remove material from the workpiece. This is in contrast to traditional machining methods such as drilling or grinding which use mechanical force to remove material.
What is Wire Electrical Discharge Machining?
Wire EDM is also known as: wire-cut EDM, wire cutting, EDN cutting, EDM wire cutting, wire burning, wire erosion, wire eroding, wire cut electric discharge machining, and ‘cheese-cutter’ EDM.
Wire electrical discharge machining (WEDM) uses a metallic wire to cut or shape a workpiece, often a conductive material, with a thin electrode wire that follows a precisely programmed path. Typically the electrode diameters range from .004″ – .012″ (.10mm – .30mm), although smaller and larger diameters are available.
During the wire cutting process there is no direct contact between the wire and the workpiece which allows for machining without causing any distortion in the path of the wire, or the shape of the material. To accomplish this, the wire is very rapidly charged to a desired voltage. The wire is also surrounded by deionized water. When the voltage reaches the correct level, a spark jumps the gap and melts a small portion of the work piece. The deionized water cools and flushes away the small particles from the gap.
The hardness of the work piece material has no detrimental effect on the cutting speed. Extrusion dies and blanking punches are very often machined by wire cutting.
How Wire EDM Works – A basic introduction to the wire EDM process.
Wire Cutting
an illustration of the wire cutting process
Illustration of wire EDM cutting. The electrode wire is held between upper and lower guides which control axis movements.
How Wire-Cut EDM Works
EDM cutting is always through the entire workpiece. To start wire machining it is first necessary to drill a hole in the workpiece or start from the edge. On the machining area, each discharge creates a crater in the workpiece and an impact on the tool. The wire can be inclined, thus making it possible to make parts with taper or with different profiles at the top and bottom. There is never any mechanical contact between the electrode and workpiece (see above). The wire is usually made of brass or stratified copper, and is between 0.1 and 0.3 mm diameter.
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