EDM machines for industrial production
How EDM machines work
An EDM machine, also known as EDM (Electrical Discharge Machining), is a high-precision machine used in industrial manufacturing to process conductive materials. These machines are particularly valuable for producing complex shapes and fine details that are difficult to achieve with conventional machining methods. EDM machines work on the principle of spark erosion, where electrical discharges (sparks) are used to remove material from a workpiece.
The operation of an EDM machine is based on electrical discharges between an electrode and the workpiece, both of which are immersed in a dielectric fluid. When a voltage is applied between the electrode and the workpiece, a spark is created which removes tiny amounts of material from the workpiece. This process is repeated continuously, removing the material layer by layer. The dielectric fluid plays a crucial role in this process as it flushes the discharge channels and removes separated material.
During erosion, the material is slightly damaged on the surface due to the heat input. This creates a so-called white edge zone, which has a different hardness to the base material. This must then be removed by polishing.
Types of EDM machines
There are two main types of EDM machines: Wire EDM machines and die-sinking EDM machines.
Wire EDM machines
The wire EDM machine uses a thin wire as an electrode, which is constantly unwound and guided through the workpiece. They are ideal for cutting precise contours and intricate shapes, especially in the tool and mold making industry. The wire moves in a programmed path to cut the desired pattern.
Die-sinking EDM machines
The die-sinking EDM machine uses a molded electrode that plunges into the workpiece. The electrode is often made of copper or graphite and corresponds to the negative shape of the desired end product. Die-sinking EDM machines are ideal for producing cavities, fine details and complex three-dimensional shapes.
Advantages of using EDM machines
EDM machines enable the machining of extremely hard materials and the production of high-precision parts with tight tolerances. As the machining process is non-contact, there is no mechanical pressure on the workpiece, which minimizes the risk of deformation and damage. In addition, EDM machines can create complex and fine details that are difficult to achieve with traditional machining methods.
Accuracy and surface quality
They achieve an accuracy in the micrometer range, often up to ±1 micrometer, which makes them ideal for the production of high-precision components. The surface finish can achieve Ra values of less than 0.1 micrometers, enabling mirror-smooth surfaces.
This high precision and quality are crucial for applications in the above-mentioned industries, where the finest details and smooth surfaces are required.
Tool and electrode materials
Tools made of extremely hard materials are used for eroding, which effectively support the removal of sparks. Hardened steel is a commonly used tool material, especially in the mold and die industry. Carbide is also often used as it offers high wear resistance and is therefore ideal for continuous use. Titanium and superalloys are used in the aerospace industry as they have to withstand extreme conditions.
The choice of electrode materials is crucial to the quality and speed of the EDM process. Copper and graphite are the most commonly used electrode materials. Copper offers excellent conductivity and is well suited for fine details and smooth surfaces. Graphite, on the other hand, is easy to machine, has high wear resistance and is ideal for machining complex shapes and large volumes.
In special applications, copper alloys and special types of graphite are also used to further optimize the performance of the electrode. Copper-tungsten electrodes combine the advantages of both materials and offer an excellent combination of conductivity and wear resistance.
Leading EDM machine manufacturers
In our manufacturers directory you will find a large number of companies that manufacture EDM machines for industrial production.
The following machine tools are frequently searched for: AEG Elotherm EDM machine, Agema EDM machine, AGIE Charmilles EDM machine, Elo-Erosion EDM machine, Mitsubishi EDM machine, Exeron EDM machine, Fanuc EDM machine, Hansen EDM machine, GF EDM machine, Hirschmann EDM machine, Ingersoll EDM machine, Makino EDM machine, ONA EDM machine, Sodick EDM machine, Vollmer EDM machine, Walter EDM machine, Seibu EDM machine, Mitsubishi Electric EDM machine, Makino EDM machine, OPS-Ingersoll EDM machine, Zimmer & Kreim EDM machine, Heun Funkenerosion EDM machine
Choosing the right EDM machine (metal)
When buying a EDM machine, several important features and specifications are crucial for optimum performance and durability:
- Accuracy and repeatability are critical, especially for applications that require tight tolerances.
- Machine size and capacity should match the size and complexity of the workpieces to be machined.
- Generator performance affects processing speed and quality, while advanced control systems enable precise and user-friendly programming.
- Electrode material compatibility is also important, as different materials such as copper and graphite offer different advantages.
- Cooling and purging systems contribute to the stability and efficiency of the machining process by removing heat and waste particles.
- Automation options, such as workpiece changers and integrated measuring systems, can significantly increase productivity.
- Service and support from the manufacturer should also be considered to ensure long-term reliability and maintenance support.
Find the EDM machine that suits your requirements now at machineselection.com.