Every electrical discharge machining and wire EDM machine operation requires the best EDM supplies available. This might seem like a logical place to skimp, but it only comes back to haunt you later on.
Wire EDM machine
The WEDM is equipped with an automatic wire threading feature, but this requires quality wire guides, as well as the wire itself. Trying to save pennies on these supplies is simply sawing off the branch on which you sit.
A poor quality wire will just not perform as you envision. The wire will tend to break, and your expensive WEDM will sit idle, while you think it is running unattended. You really can't blame the machine, it only does what it is told, for the most part!
The same holds true for the DI, or de-ionization filters. If your water is not properly treated and filtered, you are only going to have problems machining. These filters are often overlooked, yet they are critical to the operation of the machine.
The precision tooling used in set-ups and inspection for the wire EDM machine is also extremely important. Trying to do precision mold making or metal stamping die work with poor quality inspection tools is totally contradictory. If your drop indicator tells you lies, how can you ever do consistently high precision work?
Hermann Schmidt makes some of the finest tooling available. His stainless steel precision vises are unique in the industry and the accuracy is unsurpassed. The Wire EDM magnetic chuck is also the best.
The wire EDM vise is of stainless steel as well and highly accurate.
System 3R makes a complete line of tooling as well, which includes the 3Ruler and the Macro system. These supplies are quite popular and can be found in every corner of the world.
Erowa and Hirschmann also have an extensive line of tooling to complete the process.
Sinker EDM
These same companies manufacture electrode holding systems for the sinker. System 3R revolutionized the industry when they developed the MiniCube and the 20 mm shanks that can be found in nearly every EDM shop.
The tooling has gradually evolved into larger, more precise pieces, such as the 3R coins and the Macro system. Now they have the MacroJunior, 3R Ready to Run, Macro Standard, Macro High Performance, and the 3 Refix collet system.
Erowa has developed a great reputation for it's versatility and precision. These Swiss made tools include the Compact Combi Chuck, Compact chuck, and Compact Special Holders. When used with a pneumatic set-up, these holders are extremely easy to use.
The dielectric fluid used in sinker EDM is also very important and affects the outcome of the process. Along with the fluid, the EDM filter needs to be changed according to a maintenance schedule, otherwise the dielectric will be contaminated and not preform well.
Most electrodes used are of Poco graphite and Telcocopper, and are produced on a high speed milling center that uses carbide cutters. This process has shortened the lead time greatly and made life much easier for the tool maker.
By using the automatic tool changer together with a pallet changer, it is entirely possible to run the sinker EDM 24/7. It does take extensive planning, but the payback can be tremendous.
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