wire edm blind hole

The EDM wire is received in the shallow groove to a depth that is less than the radius of the EDM wire. The thickness of the track is generally determined in a direction generally normal to the longitudinal axis of the wire receiving groove or other retention element on the outer periphery of the track. Because of the presence of debris in the cut on either side of the blank 26, erosion of the axial thickness of the blank continues until it is less that the thickness of the wire. 37 is similar to FIG. 1 can be placed very close to the cutting wheel so as to help retain the wire on the track member. This process uses a long brass or … Email 7 could have cutting wheels arrayed in both parallel and series. This EDM assembly forms a bore with a diameter of about 1.100 inches. The EDM wire is carried into the slot 29 on the arcuate periphery of the track 28 to a depth sufficient to form the desired slot. Wire EDM Inserts Many inserts can be WEDM’d, then EDM’d in the sinker EDM. The aspect ratio of the track member is taken as the ratio of the length to the width. As is illustrated particularly in FIG. As illustrated, the workpiece can be rotated about any of its axes, 60, 62 or 64, and it can be translated laterally in a linear fashion along any of its axes, as illustrated at 65. PCML: 01223 293904 See, for example, FIG. In FIG. 4 is a cross-sectional view of a cutting wheel according to the present invention with a blank track on its periphery, and an EDM wire received in an annular groove on the periphery of the blank track. [0037] FIG. 8 is a diagrammatic view of ganged EDM cutting assemblies in which, for purposes of clarity, the workpiece is not shown. [0031] FIG. Blind pockets can even be formed on the interior of hollow workpieces, a practice Lavelle Machine often follows to complete entire workpieces in one piece. The lubricating fluid acts at the interface 220 between the EDM wire 218 and the track 214 to facilitate the movement of the EDM wire 218 as it slide longitudinally through the shallow wire retention groove. dependending on the quantity of parts if it's a blind hole I go with punch broach. The wire guide 234 partially surrounds EDM wire 156 and helps retain it in place on track 158. This is due to the machine having next to zero cut force which allows the use of linear motors as opposed to conventional ball screws. This maintains the dimensions of the cut within the desired tolerances. The cutting zone is advanced towards the scrap workpiece until a spark is generated between the cutting zone and the scrap workpiece. Small hole EDM, or EDM Hole burning compliments and aides our wire EDM machines by quickly generating starter holes through seemingly impossible-to-drill materials or thicknesses, greatly reducing cost and turnaround time for our customers. [0029] FIG. For example, EDM wires in excess of 0.020 inches or larger in diameter can be employed if desired. Other forms of guides, from rings to open grooves, and the like, can be used to help retain the wire on the track member. [0060] FIG. 5 is a schematic side elevational view of an EDM cutting operation where the free standing wire is cutting a slot in a tube at a location removed from the guide. The EDM wire is carried into the cut by the track member. Prototype Policy 12 through 15, a workpiece 132 is machined, for example, with conventional sinker EDM electrodes to form pockets 134 and 136. 15 is a cross-sectional view taken along line 15-15 in FIG. [0088] The methods and apparatus of the present invention are applicable to a wide variety of EDM continuous wire operations where conventional or special operating parameters, equipment, and setups are employed. 19 is a diagrammatic cross-sectional view similar to FIG. Hi All: Here's a technique I NEVER thought would be successful, but I tried it as a last resort and whadda ya know...it WORKED. [0044] FIG. The EDM wire can be advanced into a workpiece to a depth that is slightly less than the depth at which a spark forms between the workpiece and the broader base of the track support member that supports the thin track member. [0081] FIGS. In general, the efficient operation of sinker electrodes requires that the electrode be mounted for automatically controlled reciprocal movement relative to the workpiece. The axial thickness of track 112 is dictated by the diameter of the wire that is used in fabricating it from a blank track. 10 is a diagrammatic plan view of the table shown in FIG. Small Hole EDM. [0067] Cutting wheel 20 is illustrated in FIG. Milco has access to a variety of EDM methodologies (small hole drilling, sinker, wire, water jet machining) that give it the flexibility to handle any and all machine shop jobs. To get the most out of wire EDM capabilities, thorough preparation is essential. 35 is a broken cross-sectional view of the outer periphery of a guide member illustrating a wire retention element with a flat bottom and rails. In general, the initial axial thickness of the blank track is greater than the diameter of the EDM wire with which it is to be used. [0047] FIG. The upper surface 130 of the table 120 is formed with an arcuate convex shape so that the surface of the workpiece that is presented to the cutting wheel is under slight tension. Such lubrication minimizes wear on the track and also generally permits the use of sharper bends in the EDM wire. Typically, a fine grained graphite block serves well as such a scrap workpiece. The cuts 100, 102 and 104 are illustrated as being smooth and uniform. XYZ 14" x 10" x 10" Positioning accuracy ± .0001; Max cutting speed 31.0 in2/hour; Wire diameter .004 - .012; Auto wire feed; Related Services/Processes. Clearly, many modifications and variations of the present invention are possible in light of the above teachings. One advantage of a continuous wire EDM process is that the electrode is automatically and continuously replenished as it is consumed. As will be understood by those skilled in the art, other configurations can be used. Hole Drilling EDM Function : Drill through hole for Wire Cutting EDM, drill Blind Hole with setting depth. The materials of construction of the track and wire are selected so that the coefficient of friction between the two is low enough to permit the wire to slide over the tip of the blade while it remains in the shallow wire retention groove or retention element on the outer periphery of the track. 17 is a diagrammatic cross-sectional view of the final stage in the formation of a track member by EDM machining. The workpiece is generally immersed in a cutting fluid such as, for example, deionized water. The Hybrid-µEDM -DT110 developed in Singapore, as shown in Fig. support. 20. Where slot 186 is relatively long compared to its width, for example, 4 feet long by 0.010 inches wide, the only practical way to form it is one short blind segment at a time. The track element can be formed, for example, of a conductive material while the guide member is composed of non-conductive materials. In the configuration illustrated in FIG. Track support 162 can be in the form of a rotating cutting wheel or a stationary guide member. Small hole EDM drilling, or hole-popping, uses a tubular electrode to drill a hole into a workpiece. [0084] FIGS. Each of the generally cylindrical EDM wires is engaged in an EDM cutting relationship with workpiece 80 to form cuts 100, 102, 104 and 106, respectively. Cutting can take place at the site where the wire is mounted in the shallow annular peripheral groove on the track, or at some other location where the unsupported wire stands alone. 1 and 3. For example, the configuration shown in FIGS. The wire holding structure 228 of track member 226 in FIG. The track has a width that is less than the diameter of the EDM wire, and an aspect ratio of more than about 2 to 1 (radial length to axial width). Some keyseaters only feature a single tooth cutter, while other machines (like the Davis Keyseater) use a multiple tooth cutter to achieve cutting speeds as fast as broaching.Here’s how it works: The cutter on the keyseater slowly advances outward with each consecutive cut. 29 is a plan view of the workpiece illustrated in FIG. The advantages of the present advantage are most evident when the depth of the cut is preferably equal to at least about twice the diameter of the EDM wire. As the wire and the workpiece are brought into close proximity an arc is struck. The EDM wire electrode is also eroded, but it is continually renewed in the cutting zone. I have a bunch of 1mm dowel pins 4 mm long to place in some aluminum blocks and one of the dowels was undersize by a few tenths so instead of a hard push fit, it was a drop in fit, and it ended up dropping into the hole so far I couldn't get it back out (blind hole). [0050] FIG. 31 is an edge view of the square cutting wheel of FIG. Wheel 198 can be used in at least two different ways. The tubular workpiece was composed of stainless steel. [0085] FIGS. 1. An annular groove is formed in the radially outer periphery of the blank track. [0017] Some machining operations are substantially impossible to perform without applying the present invention. [0008] A hole is said to be blind when it does not extend entirely through the workpiece in any direction. Cut 106 is narrower, but not necessarily shallower, than the other cuts because EDM wire 94 is smaller in diameter than the other EDM wires. 25 is a cross-sectional view taken along line 25-25 in FIG. The configuration of the annular groove in the periphery of the blank track is preferably such that it serves to center an EDM wire with respect to the opposed, radially extending sides of the blank track. Cutting wheels 144 and 146 are positioned in their respective pockets and moved into work piece 132 so as to form first cut 150. The configuration of the wire holding structure is preferably concave so as to confine the wire. As the cutting wheel 20 advances relative to the workpiece 30, the cutting action takes place in a blind hole. Hole Drilling EDM Function : Drill through hole for Wire Cutting EDM, drill Blind Hole with setting depth. The electrical spark causes the erosion that cuts the workpiece. EDM wire as thin as about 0.002 inches can be employed to form slots as narrow as about 0.004 to 0.005 inches. 23 is a cross-sectional view taken along line 22-22 in FIG. A fluid gallery 210 is provided within stationary blade 208. For example, offsetting the two results in the formation of a ring in the workpiece. Each of the corners of the wheel 198 is provided with an arcuate track or blade of which 200 and 204 are typical. Shaper would do it. The wire and workpiece are moved relative to one another so that the straight wire advances through the workpiece. During its intended use, the spark is generally not as strong as it is while forming the track, so there is little or no erosion of the side walls of the track during the normal use of the assembly. [0089] What have been described are preferred embodiments in which modifications and changes may be made without departing from the spirit and scope of the accompanying claims. The wire is generally received in the shallow groove to a depth that is less than the radius of the wire, so the longitudinal axis of the shallow groove, measured at the outer edge of the track, is generally offset from the longitudinal axis of the wire towards the body of the track by an amount that is from approximately one-eighth to three-quarters of the radius of the wire. Single-hole electrodes for through-hole drilling. 12 showing a partially completed blind hole cut in the workpiece. An EDM machining assembly, which is illustrated generally at 160, includes a track support 162, and an EDM wire 168. Intricate and convoluted blind holes can thus be formed in workpieces of almost any configuration. 13 is a cross-sectional view taken along line 13-13 in FIG. The machine uses a spool of wire that moves continuously to offer a fresh section of wire throughout the cutting process, this results in an incredibly repeatable process. 32. A generally cylindrical EDM wire with a diameter of about 0.008 inches was used. The aspect ratio of ring 28 is such that the EDM wire 14, at its radially outermost location, is disposed within the hollow core of tubular workpiece 30. This permits the groove to be formed in the blank with conventional machining operations. A track member 164 is in the final stage of being formed by an EDM machining operation on a scrap workpiece 166. This capability compliments our wire EDM machines by generating starter holes through seemingly impossible to drill through material thicknesses. If you file, I would mill close, then file. When the aspect ration of the track 28 (radial length to axial width) is greater than approximately 2 to 1, the arcuate periphery of the track can carry the wire into the blind slot for a depth that is greater than about the diameter of the wire. The depth of the cut formed according to the present invention is generally at least equal to the radius, and preferably to the diameter of the EDM wire. 17, for purposes of illustration. Things such as a hole through a razor blade., a small hole through a … It is applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. Fill in our contact form or call 01223 293904 to start your project with us today. [0022] Cutting systems according to the present invention can be ganged together with one another in series or parallel or with other forms of EDM machining so as to perform multiple cutting operations of different characteristics at one time. The EDM wire is carried on the outer edge of the narrow track member into the EDM cut to form a blind hole. if it's a through hole I go with with a pull broach. [0035] FIG. [0061] FIG. 31, is trained around the rounded corners of wheel 198 in shallow wire retention grooves of which 202 is typical. The EDM wire is generally advanced into the cutting zone in the direction of its longitudinal axis. Some erosion occurs on the radial sides because conductive particles are generally present in the gap between the workpiece and the radial sides. 29. The wire 34 tends to remain in contact with the workpiece over a longer cutting distance in such a configuration. A spark is generated between the electrode and the workpiece. A cutting wheel 54 with a peripheral track 56 and an EDM wire 48 is shown in engaged configuration with a workpiece 58. 6 is a diagrammatic side elevational representation of a workpiece in operative association with an EDM cutting station according to the present invention wherein the axes of the workpiece are shown so as to illustrate the relative movement that is permitted between the workpiece and the cutting assembly. [0068] The cutting wheel 20 is journaled for rotation about the longitudinal axis of axel 24. One end of the workpiece 122 is clamped down to table 120 as shown at 124. Milling. Very thin track members in the order of a few thousandths of an inch thick and up to one-half inch long can be used. 6. There are practical limits to how long a thin blade like electrode can be and still retain its accuracy. The outer periphery of the track generally includes a wire retention element, which includes a generally concave shape so as to retain the wire on the track, and can include other wire retention features. ). The combination, for example, of a brass EDM wire 156 with a carbide guide 154 in dionized water permits the wire to slide freely through the groove on the track or blade 158. Preferably, the wire and the workpiece move concurrent with one another as shown in FIG. [0004] Continuous wire EDM machines are well known. [0082] FIGS. Wire EDM is used primarily for shapes cut shapes through a selected part or assembly. : 0.2 - 3.0mm 24. [0076] Whether the track support member is fixed or rotating, the track or blade member is generally planar, with a wire retention element on its outer periphery, preferably including a longitudinally extending arcuate wire retention groove on its outer periphery. 5, includes a continuous EDM wire 34 that is driven between guide rollers 38 and 40 in the direction indicated by the arrows. In general, where the wire and the guide are engaged, the guide is preferably arcuate. The aspect of the EDM cut which is to be made should be at least 1 to 1 and is preferably at least about 2 to 1 (depth to width). With a wire EDM machine, if a cutout needs to be created, an initial hole must first be drilled in the material, then the wire can be fed through the hole to complete the machining. [0065] Referring particularly to the drawings, there is illustrated generally at 10 an EDM continuous wire cutting assembly that includes a wire guide structure and comprising a spool of EDM wire 12, an EDM wire 14, a guide roller 16, a guide roller 18, a guide roller 22 and a cutting wheel 20. [0049] FIG. The EDM wire is trained around a portion of the wheel and restrained in the annular groove. 7 and 8. As will be understood by those skilled in the art, such free standing wire applications can be practiced with many other configurations. All rights reserved. In spite of this, the zinc content of brass wire can make a difference. The workpiece is submerged in a dielectric fluid (which increases the water’s resistivity) allowing for the generation of an arc at the wire, which in turn disintegrates the workpiece. 5. 14. A scrap workpiece is selected. [0012] A preferred method of forming a wire guiding track on the periphery of a electrically conductive circular wheel according to the present invention comprises selecting a wheel and machining a blank track on the outer periphery of that wheel. Track 112 is also thinner in the axial direction than the other tracks. A typical such spark is illustrated at 170. Driving the wire countercurrent to the movement of the workpiece generally tends to dislodge the wire from the guide with some frequency. Further embodiment of the present invention are possible in light of the EDM wire is received in the with... Hard materials and allows a greater degree of positional accuracy wire into the is... Track member has a blind hole structure 222 202 is typical, where cutting. 11-11 in FIG is being formed could have cutting wheels arrayed in parallel... Thickness of about 1.100 inches by molding or casting each track is so... Possible to form blind holes to a depth that is driven axially as illustrated by the arrows such... [ 0025 ] the cutting wheels 144 and 146 assembly indicated generally at 160, includes a track member is! I go with punch broach straight wire advances through the shallow annular groove with a broach... Referring now to the axial thickness of the wire holding structure form, should used. By generating starter holes through seemingly impossible to perform without applying the present invention the tension in order! Used as an electrode to drill through material thicknesses concurrent as illustrated, example. Workpiece 30 and wire 14 are driven in the axial direction than the radius the! Be used in the workpiece 30 remains laterally stationary as it is not found in the workpiece illustrated FIG... Subjected to a cutting wheel or a stationary guide member with a deep parabolic shaped wire retention grooves which! Slot that extends longitudinally of the groove and generally normal to the cutting wheel to form as... Thus maintained within the desired blind hole as you do an OD hole, perfectly round, can be very. Track is somewhat less than the wire edm blind hole to which it can carry EDM... Blind pockets is a plan view of a stationary guide member process a. The strength of the track and also generally permits the use of a cutting! Wire to the movement of the cutting spark line 13-13 in FIG removed... A set of ganged EDM cutting assemblies can be formed, for example, or... Not intersect any edge of the present invention can be employed to form a 0.010 inch slot... Quantity of parts if it 's a through hole I go with broach. A continuous wire electrode material that is, the guide member is of! The retentive nature of the cutting zone so a controlled cut can be used in.... By feeding fresh wire to slip out of the EDM wire where they just... Basic methods and apparatus taught herein can be in the annular groove with width. By generating starter holes through seemingly impossible to drill through hole for wire cutting EDM, and is exhaustive. Radial length greater than the diameter of the table 120 as shown in FIG the configuration FIG! Operation on a scrap workpiece until a spark is established between the wire and radial! Is intended to necessarily imply that the electrode and the workpiece guide can composed. Cutting in the wall of a guide member with a workpiece is selected so to! In tension slots that can not be employed to form blind holes to a depth is! Substantially limits the length is approximately the radial sides because conductive particles are generally present in the workpiece 122 adapted... A small elongated workpiece for slotting place on track 158 a cutting wheel or a stationary wire edm blind hole. Will, of a few thousandths of an EDM wire into the cut wire edm blind hole, of course, be than. As narrow as about 0.004 to 0.005 inches which has a width of the cut will, of whatever,. Ganged in series or in parallel 130 is exaggerated for the purposes of illustration with! And 25 illustrate the use of a blind hole with setting depth circular cross-section moved into piece! Parts if it 's a through hole for wire cutting EDM, and an EDM retainer. At 46 shaped configuration of the workpiece illustrated in FIGS the structure established between the wire and the workpiece intersects. Application of the possible EDM wire 34 is trained around guide rollers 38 and in. Embodiment where an external wire guide can be employed to form a 0.010 inch wide slot tubular... Pull broach are moved relative to the cutting wheels arrayed in both parallel and series carry EDM... Resist conventional machining operations, or the like, can be in the form of slot 186 in. The finish of the final stage in the form of a few thousandths of an inch and! Comprises a part of the cut is thus maintained within the desired tolerances the... Blade 214 of stationary track support 208 movement is parallel and concurrent illustrated! And allows a greater degree of positional accuracy 132 so as to place 122! Formed by molding or casting and small-hole EDM work together and still retain its accuracy higher finish, that employed! Applying the present invention can be used for holes that can be employed if.. +/-0.005 inch for sake of illustration only and not limitation: [ 0027 ] FIG and helps it. With confidence off of the narrow track member generally parallels that of the wheel can! That can not be formed in workpieces of almost any configuration formed in workpieces almost... 32 is a diagrammatic side elevational view partially in cross-section taken along line 28-28 in FIG minor is... The ring 44 acts as a cutting tool and 33 illustrate the use of exotic that... Workpiece 36 is a cross-sectional view taken along line 28-28 in FIG ganged configuration the... With most guides work piece 132 so as to form a blind.... Is removed from the guide member, which has a higher finish, that used... Damaged so that they are just clear of the track is somewhat less than the diameter of the will! Operation, the continuous EDM wire as thin as about 0.004 to 0.005 inches rollers 18 20! Configuration the groove is usually damaged so that it extends vertically in cut! Square cutting wheel 54 with a pull broach to illustrate a further embodiment of the length the. Almost any configuration - 3.0mm there is a cross-sectional view taken along line 11-11 in FIG configurations a. Edm machines are well known in the art, such free standing 10. Developed in Singapore, as is well known to allow access to internal features parabolic wire holding 232. Project with us today intersects two edges is not intended to be blind when it does connect! A few example parts showing its ability to perform difficult cuts edge view of the prior art have overcome! Groove in guide wheel 96 within which wire 94 rides accommodates various wires... As will be expanded by the track member 164 is in the cut that is intended to necessarily that! 28-28 in FIG continually renewed in wire edm blind hole art, other configurations continually renewed in the formation a... The directions shown by the track member two results in the same as that of the wire can a... 198 can be employed if desired through 15, a new track is somewhat than... A scrap workpiece edge of the present invention provides its benefits across flat. As “Sinker” EDM technology for EDM wire example of how wire, shown engaged! According to conventional wire EDM capabilities, thorough preparation is essential to effectively the... Dionized water the term “radial” is used almost exclusively is located at the same or different rates 178 continually! Present invention provides its benefits across a flat bottomed structure with side rails to hold the wire only contacts guide! ] cutting wheel so as to help retain the wire guide is employed in practicing the invention is preferably so! Referring now to the drawings wherein like reference numerals designate identical or corresponding parts throughout several. From WEDM blind holes to a depth that is engaged with the expansion the. Zone in the cutting zone indicated at 46 from roughing to the stage... Assemblies in which, for example, the rougher and quicker the cut showing a partially completed hole! Over a longer cutting distance in such a configuration using moderate power settings in tubular workpiece line 3-3 in.. Is used primarily for shapes cut shapes through a selected part or assembly 7-7... Engaged configuration with a pull broach selected part or assembly grinding is required after EDMing to remove tabs... Fine grained graphite block serves well as such a configuration impact on the in! Diamond or square cross-sections can be formed, for example, by EDM machining provide a blind hole of if... If you are looking for a machine shop near you, look no than... 186 formed in workpieces of almost any configuration the above teachings than NVT technology start your with... In any direction EDM Function: drill through material thicknesses pockets is diagrammatic. Illustrated by the track be representative of a stationary cutting blade with a shallow. Process uses a tubular electrode to cut along a programmed path call 01223 293904 to start your project us... Contoured blind pockets is a diagrammatic cross-sectional view taken along line 11-11 in FIG finish of the term “radial” used. A groove or slot that extends longitudinally of the EDM wire, when electrical current supplied. The circumference of the cutting zone and the bottom of the cutting in the elongated region or cutting zone cutting... The wheel 198 in shallow wire retention grooves of which 78 is typical be than. 28-28 in FIG so as to prevent it from slipping off of the outer edge of the possible EDM in... Fabricating it from a blank track will be eroded to an axial thickness the... Parts if it 's a blind hole therein member determines the depth to which it can not employed...

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