EDM Machine offers fine hole option

EDGE2 Ram EDM Machine is capable of burning holes as small as 0.0012 in. using tungsten rods that are 0.008 in. in diameter. With sapphire die guides as small as 0.0008 in., length-to-diameter ratios of 10:1 and 15:1 are achievable. Machine can be converted from fine hole function to standard Ram EDM functions in less than 5 min without changing dielectric fluid. It is available with 8, 16, or 24 station ATC, capable of changing electrodes as small as 0.004 in. dia.

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Advanced Technology and Superior Quality Ideal For Micromachining

AUBURN HILLS, MI-June, 2005- The EDGE2 Ram EDM machine with fine hole option has the capability to do fine diameter holes that are more accurate and precise than any water-based, hole-popping machine available. The vast majority of hole poppers in the market are water based machines that are dedicated to doing hole popping, and which have dimensional limitations on holes of around 0.010-inches in diameter.

The EDGE2 Fine Hole machine is capable of burning holes as small as 0.0012-inches (0.03048 mm) using tungsten rods that are 0.0008-inches (0.02032 mm) in diameter. With the use of sapphire die guides as small as 0.0008-inches (0.02032 mm) and a high-speed spindle, the length-to-diameter ratios of 10-to-l and 15-to-l are achievable. Fine Hole and Standard Burning

Most of the other manufacturers of oil based hole poppers that are capable of creating small holes below 0.010-inches (0.25400 mm) are bench top models. These are primarily dedicated to fine hole work, and have very limited capabilities to do other EDM work.

The EDGE2 Fine Hole machine can be converted from a fine hole function to standard Ram EDM functions in less than 5 minutes without changing dielectric fluid. And, this machine is capable of 60 amp burning with full orbiting capabilities the same as all other Makino Ram EDMs.

Also, with other bench top hole popping models, automation capability is either limited or nonexistent. The EDGE2 Fine Hole machine can be ordered with an eight-, 16- or 24-station automatic tool changer (ATC), capable of changing electrodes with diameters as small as 0.004-inches (0.10160mm).

The machine can also be ordered with an automatic guide changer (AGC) with a capacity for six different die guide sizes. This allows for users to program the burning of up to six different hole diameters with 24 different tools for maximum unattended machine time gains.

The machine's intelligent monitoring system measures the length of the electrode after each hole burn. It then determines when to put it away and take out the next available electrode of sufficient length and diameter to complete the process in a quick and high-quality fashion.

Achieving Results

With Makino's high-pressure pump system capable of pressures up to 1450 PSI, the EDGE2 Fine Hole machine provides reliable flushing through copper pipe electrodes as small as 0.004-inches (0.10160 mm). With this capability, length-to-diameter ratios greater than 25-to-l are achievable.

Due to the EDGE2 Fine Hole machine's orbiting capabilities, it is possible to size and shape specific hole diameters. This allows users to generate tapered holes or flared holes that can be square at the opening and round at the exit.

In a recent test, a series of six holes were burned 0.100-inches (2.5400 mm) deep with a 0.004-inch (0.10160 mm) diameter copper electrode. This resulted in holes with an entrance burn of 0.0048-inches (0.12192 mm) and an exit burn of 0.0045-inches (0.11430mm).

In another test, a part was generated using 0.005-inch (0.12700 mm) copper pipe going 0.200-inches (5.08000 mm) deep into a blind hole. This is accomplished using a length to diameter ratio of 40-to-l on 30 holes with maximum repeatability and reliability.

EDGE2 Fine Hole Features

The EDGE2 with fine hole option features 12 x 10 x 10 inch (304 x 254 x 254 mm) travels and weighs a sturdy 6,000 pounds (2,722 kg). The machine bed is a heavily ribbed, single piece casting. Anti-friction linear guides and bearings complete the high-performance design, combining excellent rigidity with low-mass dynamics. This heavy-duty construction, combined with the fixed table, brings high levels of rigidity to every application.

Makino's award-winning drop tank design with zero fill time and dielectric chiller completes these features. The drop tank improves many aspects of the EDM process, as the retractable tank walls provide wide-open table access for safe, simple slide-on loading and faster, more accurate setups. And the adjustable tank depth allows optimal matching of dielectric fluid level to workpiece size for overall dielectric savings.