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EDM manufacturer: EDM machine punching machine processing large depth

In the manufacturing process of the EDM machine, the hole with a diameter of less than 3mm is usually called a "small hole", and the hole with a depth to diameter ratio of more than 100 is called a "deep hole". When using the conventional metal drilling process, due to the strength limit of the drill tool, when the machining depth-to-diameter ratio exceeds 60, the machining process becomes more difficult, and the general EDM high-speed small hole (also known as fine hole) processing technology is adopted. 

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The electrode loss is usually 1:1, and the depth-to-diameter ratio of the small hole processing can only reach about 150 to 200. In order to solve the deep hole processing demand of large depth to diameter ratio (≥200) proposed in production, our company has carried out a series of process tests, and has made some progress in the near future. It has successfully realized the depth to diameter ratio of nearly 500mm. Small hole processing.


To achieve large depth to diameter ratio deep hole machining, the standard EDM high-speed small-hole machine tool specifications can not meet the processing requirements, and must develop a new large depth diameter EDM small hole machine; from the machine itself, To increase the distance between the electrode guide and the work surface, and increase the electrode feed stroke, develop the electrode guide to meet the processing needs. The test machine we selected was the SEJ-GK01 EDM high-speed small hole machine tool, and the column part of the machine was lifted and reinforced, so that the maximum distance between the electrode guide and the work surface reached 820mm. 


The test piece is made of 45 steel cold drawn bar, which has been tempered and sized to be φ10×800. The tool electrode for processing is a porous brass tube of φ2 mm×400 mm and φ2 mm×600 mm. The working fluid is deionized water. According to the processing requirements of the workpiece, the deep 800mm small hole test piece can take the method of connecting the two ends of the test piece. 


The test piece should be straightened before processing, so that the linearity error of the test piece axis is ≤0.05mm. The workpiece is loaded with a 800mm height V-shaped straight clamp, and the verticality of the fixture is tested with a precision square to correct it, and then fixed by multi-point fixing.


After the electrode and the test piece are aligned and centered, the electrode tube of length 400 mm is used, and the test processing depth is 100-150 mm. After the stability is normal, the processing can be continued. Finally, use a length of 600mm electrode tube, as far as possible to deep processing. Each electrode stops machining when the electrode collet and the guide are close to the limit position, and the electrode is replaced. 


The final machining depth exceeds 450 mm, which reduces the machining depth after the turning. The secondary processing of the turning head adopts the same technological measures as mentioned above. After the full penetration, the aperture size is between φ2.2 and φ2.5, and there may be a step of about 0.1~0.3mm at the connecting part (after several test pieces are processed) There are obvious or not obvious steps). It is estimated that the test piece is deformed during the machining process, and the axis is bent. When the head is turned, the axial line does not generate a step on the same straight line. 


There is no obvious deviation in the center of the end face of the test piece. After the processing of the test piece with obvious steps, it is very difficult to pass through the φ2×600 brass electrode tube, and it is even impossible to pass; and the φ1.5×500 brass electrode tube is used. It can be easily passed; the best quality test piece is φ2.2 shaped hole which can be easily passed through with φ2×600 brass electrode tube. In order to reduce the bending deformation of the test piece during processing, the test piece should be carefully straightened before processing. 


During the processing, pay attention to the sufficient cooling of the test piece (increase the flushing pressure and additional cooling device) to prevent the temperature from being too high and the test piece to be partially deformed. Too large, causing processing failure.


From the processing of the test piece, due to the processing range of the test machine and other conditions and process experience, the current depth of the hole and the straightness error of the small hole are still insufficient. The aperture and straightness error are about ±0.20mm or so, although it can generally meet the requirements of wire-cutting as a wire-cutting hole, however, our company intends to further research and explore the structure and supporting guide technology of EDM high-speed small hole processing machine tool, so that it is deep and small. The various process indicators of hole processing have been greatly improved.


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