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IMAX ASSOCIATES
Date:-22/12/2014
AUTHORIZED SIGNATORY
ELECTRODE MATERIAL
Theoretically, all conducting materials can be used. Material with the highest melting
point and the lowest electrical resistively are, in theory, the best. Cost analysis show that,
In EDM, electrode material; the quantity and the method of manufacturing are important
Factor and deserve careful consideration.
Silver tungsten
Copper tungsten
Copper graphites ( combination of metallic and non metallic material )
Chromium Copper
Electrolytic copper
Graphites ( non Metallic material)
Brass
Aluminum alloy
Steel
Of all above, electrolytic copper is most popular. Silver tungsten, copper Tungsten is
both quite expensive, so their use is limited to vary small & high precision parts.
After cost, other important factors in electrode selection are low wear and ease of
electrode manufacturing.
Graphite features low electrode wear and high removal rate but due to low density, it
breaks easily. When fine finish is not required we recommend graphite. Steel can be
used as an electrode but the efficiency is lower than that of copper or graphite. Its
most important EDM application is in the machining of split lines plastic mold and
dies. In these cases, the upper part of the mold or the die is used as the electrode.
Melting point c
Resistively
mm2/m
0.048
0.055
0.04
0.0236
0.0167
0.085~0.015
1083
3700
1060
~650
1539
0.0971
Density G/mm3
0.016
0.015
0.027
0.0081
0.0089
0.0015~0.0018
0.0082
0.0028
0.0087
Electrodes Material.
Work piece Material.
Surface roughness.
Spark gap.
Electrode Wears.
Removal Rate.
During sparking ( discharge ) the gap area must be flushed continuously to gat rid of
particles and residue.
If Flushing and Draining of the cavity is not good enough, increase the servo to a higher
setting. To get fine finish the vertical movement must be vary fast.
To achieve low or no electrode wear, start with a low discharge amperage, and as soon as
the whole area of the electrode contacts the work piece, increase the amperage. This will
Protect Sharp Corners or Angels.
To Set servo sensitivity bear in mind that sensitivity depends on the current; when the
current is low, servo is of small amplitude but high sensitivity.
Know & understand the discharge process.
3. DISCHRGE OPERATION PROCESS
SURFACEES AREA
Gr+
( Electrodes )
Gr-
0 mm~ 10 mm
3A ~ 6A
3A ~ 6A
10 mm ~ 25 mm
6A ~ 12A
6A ~ 12A
25 mm ~ 100 mm
12A ~ 21A
12A ~ 21A
100 mm ~ 400 mm
12A ~ 45A
21A ~ 45A
400 mm ~1600 mm
21A ~ 60A
45A ~ 60A
1600mm ~ 6400mm
6400mm
21A ~ 60A
21A ~ 60A
60A ~ 120A
120A
1. Set the Appropriate duration & amperage to produce the desired finish. Rmax
=0.5~ .8 m can be reached at at = 2 s, Where as at =500s can Produce
Rmax = 90~120m.
2. With The duration longer than 50us, duration & amperage can be Matched in
direct ratio to permit machining with no electrode wear.
When duration is short, and current high, electrode wear increases.
3. Since different material have different characteristics, its Necessary to use
Different duration setting according to the tables in the application note.
4-1.
1. Duty cycle is the off time between two pulses when no impact ionization occurs
and dielectric condition are re- established. Usually when the discharge is stable
And interval is short, efficiency is high and a protective coating will form on the
electrode. If the flushing is poor, particles are not removed and machining
efficiency decreases. So, its necessary to set the servo to raise the electrode
periodically to permit flushing.
2. No matter whether the interval is short and the amperage high or the interval is
long and the amperage low, the voltage must not change.
3. The length of the interval must be set according to the material characteristics to
get the highest efficiency.
4. T-OFF ( duty cycle ) Function:
1. T-OFF ( duty cycle ) in 1 for high speed machining.
2. If machining is unstable, adjust T Off ( duty Cycle) manually to increase
off time.
3. when amperage is too high for corresponding electrode frontal area adjust
T-Off ( duty Cycle) to increase off time, use the chart no. -3.
4-2
Sr
no.
On time Position
Current
maximum
Operation
Material
1.
10 to 20
Full
Roughing
Copper to Steel
2.
25 to 35
10 to 12 Amp
Semi finishing
Copper to Steel
3.
35 to 55
7 to 8 Amp
Finishing
Copper to Steel
4.
65 to 95
1 to 5 Amp
Super finishing
Copper to Steel
Electrode material
Melting point C
Rsistivity
mm2/m
Density G/ mm3
Silver tungsten
0.048
0.016
Copper tungsten
0.055
0.015
Copper graphite
0.04
0.027
Chromium Copper
0.0236
0.0081
Electrolytic Copper
1083
0.0167
0.0089
Graphite
3700
0.085 ~ 0.015
0.0015 ~ 0.0018
Bronze
1060
0.0082
Aluminum Alloy
Steel
1539
0.0971
0.0087
TYPE
Supply Voltage.
M - 20
M - 35
415V, 3 Phase, 50 HZ
5%
65 5%
Approx. 0.8
2 KVA.
M - 50
3 KVA.
4 KVA.
35 Amps
50 Amps
manual
manual
2 to 5000s
70 kg Approx. 80 kg Approx.
10
90kg Approx.
11
FUNCTION KEYS
1.PUMP : Used To Make Pump On/ Off.
2.SPARK : Used To Make Spark Function On/Off.
3.ATPS
4.UP
12
PERAMETER POT
1. Gap
2. SERVO
3. FLUSH
5. SPARK
6. ANTI ARC
7. ON TIME
13
8. T OFF
INTERLOCKS
1. LL LOW LEVEL :
2. UP LIMITS
3. DN LIMITS
14
TROUBLE SHOOTING
DESCRIPTION
CHECK POINTS
15
TECHNOLOGY CHART
Curren
t
T-on
4
8
12
12
duty
00
00
Gap.volt
s
45
45
flushin
g
MRR
%wear
Over
cut
Surfac
e
finish
ra
0.150
0.150
3.667
---------------
0.15
0.16
5
6
--------
0.18
0.221
0.20
1.000
0.22
1.442
0.26
16
1.663
0.28
>20
0.13
4.8
0.14
0.15
5.2
5.9
0.17
6.2
0.20
6.9
0.24
12.1
0.26
15.6
58.507
12
12
00
45
0.150
86.588
16
12
00
45
0.150
97.575
20
12
00
45
0.150
112.62
2
28
12
00
45
0.150
171.12
9
35
12
00
45
0.150
239.32
9
21
00
45
0.150
8
12
21
21
00
00
45
45
0.150
0.150
16
21
00
45
0.150
20
21
00
45
0.150
10.488
36.34
0.105
0.48
68.519
3.045
108.85
4
120
3.408
4.000
28
21
00
45
0.150
156.34
35
21
00
45
0.150
16
4.118
4
8
32
32
00
00
45
45
0.150
0.150
12
16
32
32
00
00
45
45
0.150
0.150
20
28
32
32
00
00
45
45
0.150
0.150
202.33
4
4.224
13.31
0.84
36.778
66.88
3.035
9.45
83.741
133
169.7
10.25
11
0.11
0.13
4.6
5.1
0.14
0.15
5.6
6.3
0.16
0.19
7
9.1
0.23
13.43
0.08
4.3
0.09
4.7
0.12
5.1
0.13
5.6
0.14
0.15
8.7
0.17
10.8
13.035
35
32
00
45
0.150
207.87
54
01
45
0.150
54
01
45
0.150
12
54
01
45
0.150
10.422
35.002
16
20
28
54
54
54
01
01
01
45
45
45
15.65
2.52
8.98
58.406
10.997
71.003
133
13.205
0.150
0.150
15.223
17
0.150
162.87
35
54
01
45
0.150
209.43
19.67
68
02
45
0.150
10
68
02
45
0.150
7.75
10
68
02
45
0,150
20
10
4
0.068
4.6
0.068
5
0.076
75
03
45
0.150
13
2.6
0.053
75
03
45
0.150
13
3.4
0.053
75
03
45
0.150
14
13
4
0.064
86
03
45
0.150
1.5
19
1.7
0.045
86
03
45
0.150
2.5
19
2.4
0.045
86
03
45
0.150
19
3
0.052
17
18