Precision Electrical Discharge Machining (EDM) Service

Precision Electrical Discharge Machining (EDM) service utilizes controlled electrical sparks to precisely machine hard materials and complex shapes. Ideal for intricate designs, tight tolerances, and difficult-to-machine materials, EDM ensures high accuracy, smooth finishes, and minimal material deformation in manufacturing.

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Electrical Discharge Machining (EDM) Applications

Precision Electrical Discharge Machining (EDM) applications involve creating intricate, high-precision components by eroding hard materials with electrical sparks. Ideal for complex shapes, tight tolerances, and tough materials, EDM is widely used in aerospace, medical, automotive, and tooling industries.

Industries	Applications
Aerospace and Aviation	Turbine blades, Aircraft engine components, Landing gear components
Power Generation	Steam turbine nozzles, Gas turbine vanes, Generator rotor slots
Oil and Gas	Valve seats, High-pressure nozzles, Drill bit components
Consumer Products	Mold cavities, Precision watch components, Electronic connectors
Medical Device	Surgical instrument molds, Implantable device components, Microneedle fabrication
Agricultural Machinery	Precision cutting tools, Injection molds for equipment parts, Pump impellers
Automotive	Fuel injector components, Transmission system parts, Brake system molds
Robotics	Micro-gears, Precision actuators, Custom end-effector components
Automation	Complex sensor housings, Precision drive components, High-accuracy tooling systems
Industrial Equipment	EDM wire guides, Tooling components, Precision bearings
Nuclear	Control rod mechanisms, Reactor vessel components, High-precision seals

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Electrical Discharge Machining Materials

Electrical Discharge Machining (EDM) is used to precisely shape hard materials like superalloys, titanium, and stainless steel. It’s also effective for machining conductive metals such as aluminum, copper, brass, and bronze. EDM can process a variety of materials, including carbon steel, plastics, and ceramics, offering versatility in manufacturing complex components with high precision and minimal material stress.

Materials	Grade
Superalloy	Inconel alloy, Monel alloy, Hastelloy alloy, Stellite alloy, Nimonic alloy, Rene Alloys
Titanium	Titanium TA1, TA2, Ti-6Al-4V (TC4), Ti-3Al-8V-6Cr-4Mo-4Zr (Beta C), Grade 6, Ti-5Al-5V-5Mo-3Cr (Ti5553), Ti-6.5Al-1Mo-1V-2Zr (TA15), Ti-6Al-4V ELI (Grade 23), Ti-8Al-1Mo-1V (Grade 20), 11Cr-3Al (TC11)
Aluminum	6061, 6063, 7075, 7075-T6, 6061-T6, 2024, Aluminum 5052, Aluminum 5083, Aluminum 1100, Aluminum 6082, Aluminum ADC12 (A380)
Copper	Copper C101(T2), Copper C103(T1), Copper C103(TU2), Copper C110(TU0), Beryllium Copper, Copper C102 (Oxygen-Free Copper), Copper C260 (Brass), Copper C194 (Alloy 194), Copper C175 (Chromium Copper), Copper C330 (Leaded Copper)
Brass	Brass C360, Brass C377, Brass C385, Brass C220, Brass C270, Brass C260, Brass C628, Brass C624, Brass C174, Brass C210.
Bronze	Bronze C510, Bronze C521, Bronze C608, Bronze C632, Bronze C630, Bronze C954, Bronze C863, Bronze C836, Bronze C905, Bronze C907.
Carbon steel	Steel 1018, 1020, 1025, 1040, 1060, 1045, 1215, 4130, 4140, 4340, 5140, A36, 12L14, Die steel, Alloy steel, Chisel tool steel, Spring steel, High-speed steel, Cold rolled steel, Bearing steel, SPCC
Stainless steel	Steel 1018, 1020, 1025, 1040, 1060, 1045, 1215, 4130, 4140, 4340, 5140, A36, 12L14, Die steel, Alloy steel, Chisel tool steel, Spring steel, High-speed steel, Cold rolled steel, Bearing steel, SPCC
Plastic	ABS, Nylon (PA), Acetal (POM), UHMW (Ultra-High Molecular Weight Polyethylene), PTFE (Teflon), Polycarbonate (PC), Polyethylene (PE), PVC, PEEK, Delrin, Polypropylene (PP).
Ceramic	Alumina, Zirconia, Aluminum-based Silicon Carbide

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Surface Treatment for EDM Parts

Surface treatment for EDM parts enhances durability, corrosion resistance, and appearance. Techniques like polishing, coating, and nitriding improve the surface integrity, reduce wear, and extend the lifespan of EDM-manufactured components, ensuring optimal performance in demanding industrial applications.

Items	Suggestions
General Tolerances	±0.1 mm (for most standard EDM operations)

Precision Tolerances	±0.005 mm (for high-precision components)

Min Wall Thickness	0.2 mm (depending on material and machining conditions)

Min Boring Size	0.3 mm (for fine detail work in small features)

Max Boring Depth	300 mm (depending on the machine and material constraints)

Maximum Part Size	800 mm x 800 mm x 800 mm (varies by machine and material)

Minimum Part Size	0.5 mm x 0.5 mm (for small and intricate details)

Prototyping	1 to 50 parts (for initial test runs or low-volume production)

Low Volume	50 to 500 parts (efficient for small production runs with high precision)

Mass Production	500+ parts (possible with appropriate tooling and process optimization)

Lead Time	1 to 4 weeks (depending on complexity, material, and quantity)

Items	Suggestions
Radii and Fillets	Use radii or fillets with a minimum radius of 0.2 mm to reduce tool wear and improve machining efficiency. Avoid sharp internal corners to ensure smooth electrical discharge.

Hole Design	Ensure a minimum hole diameter of 0.3 mm for EDM. For deep holes, consider a depth-to-diameter ratio of 5:1 or lower to ensure effective machining and avoid excessive electrode wear.

Surface Finish	Specify surface finish based on part requirements: Ra 0.8 µm for standard parts Ra 0.2 µm for high-precision components Ra 0.05 µm for optical-quality surfaces.

Wall Thickness	Maintain consistent wall thickness, with a minimum of 0.2 mm to ensure structural integrity during machining and prevent distortion.

Tolerance	Standard tolerance for EDM: ±0.1 mm for general applications, and ±0.005 mm for high-precision parts. Use tighter tolerances only when necessary to avoid higher costs.

Hole Placement	Position holes with a minimum center-to-center distance of 0.5 mm. Avoid placing holes too close to edges or other holes to ensure proper spark discharge and avoid tool interference.

Part Orientation	Position the part to minimize electrode changes and reduce machining time. Plan for accessible areas to avoid excessive setups or fixturing changes during the process.

Electrode Design	Use appropriate electrode material (e.g., copper or graphite) for the workpiece material. Ensure proper electrode geometry for optimal spark distribution and better surface quality.

Sharp Edges and Corners	Avoid sharp edges and corners. Use radii or chamfers to ensure better spark discharge, reduce electrode wear, and improve part strength.

Material Selection	Select materials with appropriate conductivity and hardness for EDM. Materials like carbide, tool steel, and titanium alloys are commonly processed, but harder materials require specific electrodes.

Cutting Speed and Power Settings	Set cutting speeds and power settings based on the material's characteristics and the desired finish. Adjust settings for optimal spark energy, especially for intricate details.

Pocket Design	Ensure pockets have smooth transitions and avoid deep, narrow pockets. Rounded corners (minimum radius 0.5 mm) are recommended for better spark distribution and easier removal of material.

Precision Electrical Discharge Machining (EDM) Service

Electrical Discharge Machining (EDM) Applications

Electrical Discharge Machining Materials

Surface Treatment for EDM Parts

EDM Machining Tolerance Suggestions

EDM Machining Design Guideline

Frequently Asked Questions

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