Considering you searched for such a complex topic, we can already assume that you know exactly what electrical discharge machining is. But, on the off chance you do not or just need a refresher, electrical discharge machining (or EDM) can be defined as the process of metal fabrication that uses electric sparks to shape metal into desired forms.
If you are thinking to yourself that EDM sounds an awful lot like wire erosion, wire burning, spark erosion, spark machining, or die sinking, that is due to the fact that they are all practically one and the same- just different machines that serve slightly different purposes.
So how are these machines able to use electricity to achieve cuts in metal? Well, this isn’t exactly a new, 21st-century process. Back in 1770, an English physicist by the name of Joseph Priestley took notice that electrical sparks were able to erode metals. From there, the methods of die and wire EDM emerged. From punching holes to creating tools essential for the workplace, we as consumers benefit from the effects of EDM every day.
You have probably heard that dielectric fluid is essential in the EDM process. There are four types of dielectric fluids typically used in EDM machining- water/water-based additives, hydrocarbons and biodiesel oils, gas-based fluid, and powder-based fluid.
Water-based is readily available and environmentally friendly but sometimes will not produce the desired results. Hydrocarbons and biodiesel oils were used initially in EDM machining but gave off noxious fumes. But, there are safer and more environmentally friendly hydrocarbon and biodiesel oil options being used today. Gas-based are the least dangerous and easiest to come by, with gases like oxygen being used for machining. Powder-based is a new technique that many machinists tend to favor.
Dielectric fluid is a liquid that helps insulate the machine and prevent electric discharges. So hang on, don’t we need discharges to cut the material? That sounds pretty contradictory, don’t you think?
It turns out, large amounts of electricity on metal can become destructive. To avoid damaging the metal during and after cutting, dielectric fluid is used to control pulsing electricity and absorb excess heat. Without dielectric fluid to cool things down, the metal being cut and shaped could collapse, and you would never be able to finish an EDM project.
EDM affects us every day. Sure it sounds incredibly complicated, but that is why trained machinists know the ins and outs of EDM. Ephrata Precision Parts is a trusted company that provides electrical discharge machining services in Ephrata, Pennsylvania. Since 1972, Ephrata Precision Parts has been specializing in the machining industry, adding machines and machining methods for everyones’ needs. Their wire, sinking, and hole popping EDM will expertly give customers precise results every time.
