Sinker EDM
Unleash Precision with Sundi's EDM Services: Where Advanced Machinery Meets Expertise. Elevate Your Projects with Our Exceptional Quality, Swift Turnaround, and Competitive Rates, Ensuring Your Market Dominance.
What Is Sinker EDM
Sinker EDM is a specialized electrical discharge machining process. It uses a shaped electrode, often made of copper or graphite, submerged in an insulating fluid along with the workpiece. Electrical discharges occur between the electrode and the workpiece, eroding the material to create the desired shape. This method is ideal for making intricate cavities or complex shapes in conductive materials that are hard to machine traditionally.
We have 5 state-of-the-art Makino and Sodick precision EDM machines, meticulously designed to tackle your challenges in processing hard alloys and complex components. These high-end machines ensure ultra-high precision and exceptional processing efficiency, guaranteeing the perfect fulfillment of your precision parts manufacturing needs.
Why Choose Us for Sinker EDM
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Advanced Technology
We employ state-of-the-art sinker EDM machines that ensure high precision and intricate details.
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Expertise and Experience
Our team is capable of handling complex and delicate projects with utmost precision.
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Customization Capabilities
We specialize in creating custom electrodes to meet unique project requirements.
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Quality and Precision
we are committed to delivering projects within efficient timeframes without compromising on quality or precision.
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Quality Assurance and Precision
We adhere to strict quality control protocols and use precision measuring tools to ensure the accuracy and quality.
- Quality Assurance
- OEM/ODM Service
- Cost Saving
- Fast Delivery
How Can We Operate and Control The Quality?
Operating and controlling the quality during Sinker EDM (Electrical Discharge Machining) involves a systematic approach to ensure precision and accuracy in the machining process.
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Machine Calibration and Setup
Before starting any EDM operation, the machine needs to be properly calibrated. This includes aligning the electrode and workpiece, setting the correct parameters, and ensuring the dielectric fluid is at the right level.
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Electrode Selection
Choose the appropriate electrode material (usually copper or graphite) and shape for the specific job. The electrode should match the desired geometry of the final workpiece.
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Dielectric Fluid Management
Maintain the dielectric fluid in the machine. It acts as an insulator and coolant during the EDM process. Regularly check and filter the dielectric fluid to ensure it remains in good condition.
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Electrode Wear Monitoring
During EDM, the electrode gradually wears down. Use monitoring systems to track electrode wear and replace it when necessary to maintain accuracy.
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Toolpath Programming
Develop a precise toolpath program that guides the electrode to erode the workpiece according to the desired design. Ensure the program accounts for electrode wear and compensates accordingly.
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Quality Control Checks:
Perform in-process quality control checks at specific intervals. This may include measuring workpiece dimensions, surface finish, and inspecting for defects.
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Feedback Systems
Utilize feedback systems that monitor the EDM process in real-time. These systems can adjust parameters on the fly to maintain accuracy and quality.
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Finishing Operations:
After EDM, additional finishing operations like polishing or grinding may be required to achieve the desired surface finish and tolerances.
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Operator Training
Ensure that operators are well-trained in Sinker EDM operations and quality control procedures. Skilled operators can make critical decisions during the machining process.
The Choice of Electrode Material
Electrodes play a crucial role in EDM, directly impacting machining quality and precision. Therefore, selecting the appropriate electrode material is essential for achieving desired results.
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Copper
Copper is a common choice due to its excellent electrical conductivity. It allows for efficient electrical discharge machining (EDM) and is suitable for various workpiece materials.
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Copper Tungsten Alloy
Copper tungsten combines the conductivity of copper with the high melting point and wear resistance of tungsten. This alloy is suitable for EDM tasks involving high-temperature materials and challenging machining tasks.
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Graphite
Graphite electrodes are known for their high conductivity and wear resistance. They are often used for EDM applications involving hard materials and complex shapes.
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Aluminum
Aluminum electrodes are used for specific applications, especially when EDMing aluminum workpieces. They are lightweight and suitable for certain special requirements.
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Silver
Silver electrodes offer exceptional electrical conductivity and are employed for the precision machining of conductive materials.
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Molybdenum
Molybdenum electrodes are used in high-temperature EDM applications due to their high melting point and wear resistance.
Features and Description
The specific values can vary based on the EDM equipment used, the material being machined, and the specific setup and process parameters chosen. This table provides a general overview of what precision EDM can achieve.
| Feature | Description |
|---|---|
| Accuracy | ±0.005 mm to±0.015 mm(Typical) |
| Surface Roughness(Ra) | 0.1 to 1.6 μm(Depends on process parameters) |
| Surface Finish | Can achieve mirror-like finishes |
| Complexity Handling | Suitable for complex geometries and intricate shapes |
| Material Compatibility | Effective for hard materials like titanium, hardened steel |
| Depth of Cut | Up to 300 mm (Varies based on machine capability) |
| Tolerance Range | Typically ±0.010 mm, finer tolerances achievable |
| Minimum Feature Size | As small as 0.1 mm(Depending on electrode size) |
Common Issues When Sinker EDM Processing
When processing with Sinker EDM (Electrical Discharge Machining), several common issues may arise. Addressing these challenges is key to maintaining efficiency and quality in the machining process:
- Electrode Wear: One of the primary issues in sinker EDM is electrode wear. Over time, the electrode erodes, which can affect the precision of the machined part. Managing and compensating for this wear is crucial to maintain accuracy.
- Inconsistent Surface Finish: Achieving a consistent surface finish can be challenging, especially when machining complex geometries or working with different materials. Surface finish can be affected by factors like discharge energy, electrode material, and dielectric fluid type.
- Inaccurate Machining Due to Poor Setup: Incorrect setup of the machine, including alignment and positioning of the electrode, can lead to inaccuracies in the machined part. Precision in setup is crucial for the success of the process.
- Difficulty in Machining Thin Walls: Sinker EDM can sometimes struggle with thin-walled features due to the risk of vibration or deformation during the process. Special care and advanced strategies are required to successfully machine these delicate structures.
- Material Removal Rate (MRR) Challenges: Balancing material removal rate with accuracy and surface finish is a common challenge. Higher MRR can lead to reduced accuracy and a rougher surface, requiring a trade-off based on the project requirements.
- Heat Affected Zone (HAZ): Sinker EDM produces a heat-affected zone around the machined area, which can alter the material properties. This needs to be considered, especially in precision applications.
- Debris Removal Issues: Efficient removal of debris (resulting from the EDM process) from the machining area is vital. Inadequate removal can affect machining quality and increase wear on the electrode.
- Dielectric Fluid Management: Maintaining the quality of the dielectric fluid is essential for efficient machining. Contaminated or degraded fluid can lead to poor machining results and increased electrode wear.
- Cost and Time Efficiency: Sinker EDM is generally more time-consuming and costly compared to other machining processes, particularly for larger volumes. Efficient process management is necessary to keep costs and time in check.
- Complex Programming and Operation: Programming for sinker EDM can be complex, especially for intricate shapes and deep cavities. Skilled operators with thorough knowledge of EDM programming and operation are essential.
