Electrical discharge machining

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process. Yet, any practical application involves many aspects that may also need to be considered. For instance, the removal of the debris from the inter-electrode volume is likely to be always partial. Thus the electrical properties of the dielectric in the inter-electrodes volume can be different from their nominal values and can even vary with time. The inter-electrode distance, often also referred to as spark-gap, is the result of the control algorithms of the specific machine used. The control of such a distance appears logically to be central to this process. Also, not all of the current between the dielectric is of the ideal type described above: the spark-gap can be short-circuited by the debris. The control system of the electrode may fail to react quickly enough to prevent the two electrodes (tool and workpiece) from coming into contact, with a consequent short circuit. This is unwanted because a short circuit contributes to material removal differently from the ideal case. The flushing action can be inadequate to restore the insulating properties of the dielectric so that the current always happens in the point of the inter-electrode volume (this is referred to as arcing), with a consequent unwanted change of shape (damage) of the tool-electrode and workpiece. Ultimately, a description of this process in a suitable way for the specific purpose at hand is what makes the EDM area such a rich field for further investigation and research.

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a single direction, usually the vertical direction (i.e. z-axis). This resembles the sink of the tool into the dielectric liquid in which the workpiece is immersed, so, not surprisingly, it is often referred to as die-sinking EDM (also called conventional EDM and ram EDM). The corresponding machines are often called sinker EDM. Usually, the electrodes of this type have quite complex forms. If the final geometry is obtained using a usually simple-shaped electrode which is moved along several directions and is possibly also subject to rotations, often the term EDM milling is used.

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the machining of the part, the off time allows the flushing of dielectric fluid through a nozzle to clean out the eroded debris. Insufficient debris removal can cause repeated strikes in the same location which can lead to a short circuit. Modern controllers monitor the characteristics of the arcs and can alter parameters in microseconds to compensate. The typical part geometry is a complex 3D shape, often with small or odd shaped angles. Vertical, orbital, vectorial, directional, helical, conical, rotational, spin, and indexing machining cycles are also used.

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continuously replacing the tool-electrode during a machining operation. This is what happens if a continuously replaced wire is used as electrode. In this case, the correspondent EDM process is also called wire EDM. The tool-electrode can also be used in such a way that only a small portion of it is actually engaged in the machining process and this portion is changed on a regular basis. This is, for instance, the case when using a rotating disk as a tool-electrode. The corresponding process is often also referred to as EDM grinding.

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random locations between the electrode and the workpiece. As the base metal is eroded, and the spark gap subsequently increased, the electrode is lowered automatically by the machine so that the process can continue uninterrupted. Several hundred thousand sparks occur per second, with the actual duty cycle carefully controlled by the setup parameters. These controlling cycles are sometimes known as "on time" and "off time", which are more formally defined in the literature.

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sides of the wire to the work piece, causing erosion. This "overcut" is necessary, for many applications it is adequately predictable and therefore can be compensated for (for instance in micro-EDM this is not often the case). Spools of wire are long — an 8 kg spool of 0.25 mm wire is just over 19 kilometers in length. Wire diameter can be as small as 20 μm (0.79 mils) and the geometry precision is not far from ± 1 μm (0.039 mils).

707: 430: 162:'s group in the 1960s at Andrew Engineering Company for milling and grinding machines. Master drawings were later produced by computer numerical controlled (CNC) plotters for greater accuracy. A wire-cut EDM machine using the CNC drawing plotter and optical line follower techniques was produced in 1974. Dulebohn later used the same plotter CNC program to directly control the EDM machine, and the first CNC EDM machine was produced in 1976. 596: 720: 683: 438: 182: 372:

energies the models are inadequate to explain the experimental data. All these models hinge on a number of assumptions from such disparate research areas as submarine explosions, discharges in gases, and failure of transformers, so it is not surprising that alternative models have been proposed more recently in the literature trying to explain the EDM process.

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generators and control systems on their machines are not always easily available to their user. This is a barrier to describing unequivocally the technological parameters of the EDM process. Moreover, the parameters affecting the phenomena occurring between tool and electrode are also related to the controller of the motion of the electrodes.

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altered mechanical properties due to an increased temperature caused by the passage of electric current. The authors' simulations showed how they might explain EDM better than a thermal model (melting or evaporation), especially for small discharge energies, which are typically used in μ-EDM and in finishing operations.

296:(colloquially also called sparks) happen, each contributing to the removal of material from both tool and workpiece, where small craters are formed. The size of the craters is a function of the technological parameters set for the specific job at hand. They can be with typical dimensions ranging from the nanoscale (in 399: 343:

amplitude of each pulse constitutes the open circuit voltage. Thus, the maximum duration of discharge is equal to the duration of a pulse of voltage in the train. Two pulses of current are then expected not to occur for a duration equal or larger than the time interval between two consecutive pulses of voltage.

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to produce stamped flats from cutout sheet blanks of bronze, silver, or low proof gold alloy. For badges these flats may be further shaped to a curved surface by another die. This type of EDM is usually performed submerged in an oil-based dielectric. The finished object may be further refined by hard

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Further models of what occurs during electric discharge machining in terms of heat transfer were developed in the late eighties and early nineties. It resulted in three scholarly papers: the first presenting a thermal model of material removal on the cathode, the second presenting a thermal model for

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flowing through the electrode as a flushing agent and dielectric. The electrode tubes operate like the wire in wire-cut EDM machines, having a spark gap and wear rate. Some small-hole drilling EDMs are able to drill through 100 mm of soft or hardened steel in less than 10 seconds, averaging 50%

746:

On wire-cut EDM machines, small hole drilling EDM is used to make a through hole in a workpiece through which to thread the wire for the wire-cut EDM operation. A separate EDM head specifically for small hole drilling is mounted on a wire-cut machine and allows large hardened plates to have finished

568:

Wire-cutting EDM is commonly used when low residual stresses are desired, because it does not require high cutting forces for removal of material. If the energy per pulse is relatively low (as in finishing operations), little change in the mechanical properties of a material is expected due to these

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Given the many available models, it appears that the material removal mechanism in EDM is not yet well understood and that further investigation is necessary to clarify it, especially considering the lack of experimental scientific evidence to build and validate the current EDM models. This explains

342:

In generators based on transistor control, the user is usually able to deliver a train of pulses of voltage to the electrodes. Each pulse can be controlled in shape, for instance, quasi-rectangular. In particular, the time between two consecutive pulses and the duration of each pulse can be set. The

307:

A further strategy consists in using a set of electrodes with different sizes and shapes during the same EDM operation. This is often referred to as multiple electrode strategy, and is most common when the tool electrode replicates in negative the wanted shape and is advanced towards the blank along

133:

Simultaneously but independently, an American team, Harold Stark, Victor Harding, and Jack Beaver, developed an EDM machine for removing broken drills and taps from aluminium castings. Initially constructing their machines from under-powered electric-etching tools, they were not very successful. But

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0.02 mm (0.79 mils) wire, though the average cutting kerf that achieves the best economic cost and machining time is 0.335 mm (13.2 mils) using Ø 0.25 mm (9.8 mils) brass wire. The reason that the cutting width is greater than the width of the wire is because sparking occurs from the

420:

The on time setting determines the length or duration of the spark. Hence, a longer on time produces a deeper cavity from each spark, creating a rougher finish on the workpiece. The reverse is true for a shorter on time. Off time is the period of time between sparks. Although not directly affecting

416:

These sparks usually strike one at a time, because it is very unlikely that different locations in the inter-electrode space have the identical local electrical characteristics which would enable a spark to occur simultaneously in all such locations. These sparks happen in huge numbers at seemingly

371:

These models give the most authoritative support for the claim that EDM is a thermal process, removing material from the two electrodes because of melting or vaporization, along with pressure dynamics established in the spark-gap by the collapsing of the plasma channel. However, for small discharge

338:

In both categories, the primary parameters at setup are the current and frequency delivered. In RC circuits, however, little control is expected over the time duration of the discharge, which is likely to depend on the actual spark-gap conditions (size and pollution) at the moment of the discharge.

412:

Sinker EDM, also called ram EDM, cavity type EDM or volume EDM, consists of an electrode and workpiece submerged in an insulating liquid such as, more typically, oil or, less frequently, other dielectric fluids. The electrode and workpiece are connected to a suitable power supply. The power supply

346:

The maximum current during a discharge that the generator delivers can also be controlled. Because other sorts of generators may also be used by different machine builders, the parameters that may actually be set on a particular machine will depend on the generator manufacturer. The details of the

311:

In any case, the severity of the wear is strictly dependent on the technological parameters used in the operation (for instance: polarity, maximum current, open circuit voltage). For example, in micro-EDM, also known as μ-EDM, these parameters are usually set at values which generates severe wear.

100:

of the liquid, and produces an electric arc. As a result, material is removed from the electrodes. Once the current stops (or is stopped, depending on the type of generator), new liquid dielectric is conveyed into the inter-electrode volume, enabling the solid particles (debris) to be carried away

354:

These authors conducted their research in the field of μ-EDM, but the same approach can be used in any EDM operation. This would enable the user to estimate directly the electrical parameters that affect their operations without relying upon machine manufacturer's claims. When machining different

581:

Fast hole drilling EDM was designed for producing fast, accurate, small, deep holes. It is conceptually akin to sinker EDM but the electrode is a rotating tube conveying a pressurized jet of dielectric fluid. It can make a hole an inch deep in about a minute and is a good way to machine holes in

564:

Along with tighter tolerances, multi axis EDM wire-cutting machining centers have added features such as multi heads for cutting two parts at the same time, controls for preventing wire breakage, automatic self-threading features in case of wire breakage, and programmable machining strategies to

224:

Electrical discharge machining is a machining method primarily used for hard metals or those that would be very difficult to machine with traditional techniques. EDM typically works with materials that are electrically conductive, although methods have also been proposed for using EDM to machine

375:

Among these, the model from Singh and Ghosh reconnects the removal of material from the electrode to the presence of an electrical force on the surface of the electrode that could mechanically remove material and create the craters. This would be possible because the material on the surface has

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The work piece may undergo a significant thermal cycle, its severity depending on the technological parameters used. Such thermal cycles may cause formation of a recast layer on the part and residual tensile stresses on the work piece. If machining takes place after heat treatment, dimensional

315:

The problem of wear to graphite electrodes is being addressed. In one approach, a digital generator, controllable within milliseconds, reverses polarity as electro-erosion takes place. That produces an effect similar to electroplating that continuously deposits the eroded graphite back on the

291:

Ideally, EDM can be seen as a series of breakdown and restoration of the liquid dielectric in-between the electrodes. However, caution should be exerted in considering such a statement because it is an idealized model of the process, introduced to describe the fundamental ideas underlying the

125:

Two Soviet scientists, B. R. Lazarenko and N. I. Lazarenko, were tasked in 1943 to investigate ways of preventing the erosion of tungsten electrical contacts due to sparking. They failed in this task but found that the erosion was more precisely controlled if the electrodes were immersed in a

363:

The first serious attempt at providing a physical explanation of the material removal during electric discharge machining is perhaps that of Van Dijck. Van Dijck presented a thermal model together with a computational simulation to explain the phenomena between the electrodes during electric

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The presence of these small craters on the tool results in the gradual erosion of the electrode. This erosion of the tool-electrode is also referred to as wear. Strategies are needed to counteract the detrimental effect of the wear on the geometry of the workpiece. One possibility is that of

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To obtain a specific geometry, the EDM tool is guided along the desired path very close to the work; ideally it should not touch the workpiece, although in reality this may happen due to the performance of the specific motion control in use. In this way, a large number of current discharges

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to 80% wear rate. Holes of 0.3 mm to 6.1 mm can be achieved in this drilling operation. Brass electrodes are easier to machine but are not recommended for wire-cut operations due to eroded brass particles causing "brass on brass" wire breakage, therefore copper is recommended.

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materials too hard for twist-drill machining. This EDM drilling type is used largely in the aerospace industry, producing cooling holes into aero blades and other components. It is also used to drill holes in industrial gas turbine blades, in molds and dies, and in bearings.

89:. The process depends upon the tool and work piece not making physical contact. Extremely hard materials like carbides, ceramics, titanium alloys and heat treated tool steels that are very difficult to machine using conventional machining can be precisely machined by EDM. 158:(NC) machines were conversions of punched-tape vertical milling machines. The first commercially available NC machine built as a wire-cut EDM machine was manufactured in the USSR in 1967. Machines that could optically follow lines on a master drawing were developed by 476:, is fed through the workpiece, submerged in a tank of dielectric fluid, typically deionized water. Wire-cut EDM is typically used to cut plates as thick as 300mm and to make punches, tools, and dies from hard metals that are difficult to machine with other methods. 1008:

Lazarenko, B.R.; Duradzhi, V.N.; Bryantsev, I.V. "Effect of Incorporating an additional inductance on the characteristics of anode and cathode processes. (O Vliyanii Vklyucheniya Dopolnitel'noi Induktivnosti Na Kharakteristiki Anodnogo I Katodnogo Protsessov)".

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the erosion occurring on the anode and the third introducing a model describing the plasma channel formed during the passage of the discharge current through the dielectric liquid. Validation of these models is supported by experimental data provided by AGIE.

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from work pieces. In this application, the process is termed "metal disintegration machining" or MDM. The metal disintegration process removes only the center of the broken tool or fastener, leaving the hole intact and allowing a ruined part to be reclaimed.

698:) by the coinage (stamping) process, the positive master may be made from sterling silver, since (with appropriate machine settings) the master is significantly eroded and is used only once. The resultant negative die is then hardened and used in a 978:

Lazarenko, B.R.; Mikhailov, V.V.; Gitlevich, A.E.; Verkhoturov, A.D.; Anfimov, I.S. "Distribution of elements in surface layers during electric spark alloying. (Raspredelenie Elementov V Poverkhnostnykh Sloyakh Pri Elektroiskrovom Legirovanii)".

154:) from hardened steel. The tool electrode in wire EDM is simply a wire. To avoid the erosion of the wire causing it to break, the wire is wound between two spools so that the active part of the wire is constantly changing. The earliest 665:

industries, but is becoming a common method of making prototype and production parts, especially in the aerospace, automobile and electronics industries in which production quantities are relatively low. In sinker EDM, a

400: 65:, is a metal fabrication process whereby a desired shape is obtained by using electrical discharges (sparks). Material is removed from the work piece by a series of rapidly recurring current discharges between two 350:

A framework to define and measure the electrical parameters during an EDM operation directly on inter-electrode volume with an oscilloscope external to the machine has been recently proposed by Ferri

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Eubank, Philip T.; Patel, Mukund R.; Barrufet, Maria A.; Bozkurt, B. (1993). "Theoretical models of the electrical discharge machining process. III. The variable mass, cylindrical plasma model".

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axis, giving rise to the ability to cut tapered and transitioning shapes (circle on the bottom, square at the top for example). The upper guide can control axis movements in the GCode standard,

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generates an electrical potential between the two parts. As the electrode approaches the workpiece, dielectric breakdown occurs in the fluid, forming a plasma channel, and a small spark jumps.

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dielectric fluid. This led them to invent an EDM machine used for working difficult-to-machine materials such as tungsten. The Lazarenkos' machine is known as an R-C-type machine, after the

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Dibitonto, Daryl D.; Eubank, Philip T.; Patel, Mukund R.; Barrufet, Maria A. (1989). "Theoretical models of the electrical discharge machining process. I. A simple cathode erosion model".

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discharge machining. However, as Van Dijck himself admitted in his study, the number of assumptions made to overcome the lack of experimental data at that time was quite significant.

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Patel, Mukund R.; Barrufet, Maria A.; Eubank, Philip T.; Dibitonto, Daryl D. (1989). "Theoretical models of the electrical discharge machining process. II. The anode erosion model".

105:. After a current flow, the voltage between the electrodes is restored to what it was before the breakdown, so that a new liquid dielectric breakdown can occur to repeat the cycle. 1195:

Liu YH, Li XP, Ji RJ, Yu LL, Zhang HF, Li QY (2008). "Effect of technological parameter on the process performance for electric discharge milling of insulating Al2O3 ceramic".

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Also, the open circuit voltage (i.e. the voltage between the electrodes when the dielectric is not yet broken) can be identified as steady state voltage of the RC circuit.

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units. The water flushes the cut debris away from the cutting zone. Flushing is an important factor in determining the maximum feed rate for a given material thickness.

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that can machine blind or through holes. EDM drills bore holes with a long brass or copper tube electrode that rotates in a chuck with a constant flow of distilled or

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Lazarenko, B.R.; Lazarenko, N.I. "Electric spark machining of metals in water and electrolytes. (Elektroiskrovaya Obrabotka Metallov V Vode I Elektrolitakh)".

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electrode. In another method, a so-called "Zero Wear" circuit reduces how often the discharge starts and stops, keeping it on for as long a time as possible.

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Morgan, C. J.; Vallance, R. R.; Marsh, E. R. (2004). "Micro machining glass with polycrystalline diamond tools shaped by micro electro discharge machining".

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arrangement produced practical machines. Stark, Harding, and Beaver's machines produced 60 sparks per second. Later machines based on their design used

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There is no direct contact between tool and work piece. Therefore, delicate sections and weak materials can be machined without perceivable distortion.

101:

and the insulating properties of the dielectric to be restored. Adding new liquid dielectric in the inter-electrode volume is commonly referred to as

1726:

Kucukturk, G.; Cogun, C. (2010). "A New Method for Machining of Electrically Nonconductive Workpieces Using Electric Discharge Machining Technique".

703:(glass) or soft (paint) enameling, or electroplated with pure gold or nickel. Softer materials such as silver may be hand engraved as a refinement. 1053: 1024: 994: 617: 1894: 758:. Gas flow through these small holes allows the engines to use higher temperatures than otherwise possible. The high-temperature, very hard, 1807: 762:

alloys employed in these blades makes conventional machining of these holes with high aspect ratio extremely difficult, if not impossible.

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Two broad categories of generators, also known as power supplies, are in use on EDM machines commercially available: the group based on

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The wire-cut process uses water as its dielectric fluid, controlling its resistivity and other electrical properties with filters and

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without the need for heat treatment to soften and re-harden them. This method can be used with any other metal or metal alloy such as

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Mohri, N.; Fukuzawa, Y.; Tani, T.; Saito, N.; Furutani, K. (1996). "Assisting Electrode Method for Machining Insulating Ceramics".

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Master at top, badge die workpiece at bottom, oil jets at left (oil has been drained). Initial flat stamping will be "dapped", see

1925: 1764:"Electrical Discharge Machining of Alumina Using Cu-Ag and Cu Mono- and Multi-Layer Coatings and ZnO Powder-Mixed Water Medium" 843:

Very small work pieces can be machined where conventional cutting tools may damage the part from excess cutting tool pressure.

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EDM control panel (Hansvedt machine). Machine may be adjusted for a refined surface (electropolish) at end of process.

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Narasimhan, J.; Yu, Z.; Rajurkar, K. P. (2005). "Tool Wear Compensation and Path Generation in Micro and Macro EDM".

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The upper and lower diamond guides are usually accurate to 0.004 mm (0.16 mils), and can have a cutting path or

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materials in the same setup conditions, the actual electrical parameters of the process are significantly different.

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more powerful sparking units, combined with automatic spark repetition and fluid replacement with an electromagnetic

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electrode is machined into the desired (negative) shape and fed into the workpiece on the end of a vertical ram.

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Singh, A.; Ghosh, A. (1999). "A thermo-electric model of material removal during electric discharge machining".

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low residual stresses, although material that hasn't been stress-relieved can distort in the machining process.

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Ability to machine complex shapes that would otherwise be difficult to produce with conventional cutting tools.

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Weng, F. T.; Shyu, R. F.; Hsu, C. S. (2003). "Fabrication of micro-electrodes by multi-EDM grinding process".

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Difficulties have been encountered in the definition of the technological parameters that drive the process.

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A good surface finish can be obtained; a very good surface may be obtained by redundant finishing paths.

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For the creation of dies for producing jewelry and badges, or blanking and piercing (through use of a

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circuits that produced thousands of sparks per second, significantly increasing the speed of cutting.

2196: 2053: 1068: 909: 830: 818: 288:, and any other process whose material removal mechanism is essentially based on mechanical forces). 261: 2186: 802: 606: 2472: 2276: 2261: 2201: 2163: 2103: 1823: 1288: 893: 610: 250: 2498: 2306: 2286: 2181: 687: 2405: 2266: 1965: 1047: 1018: 988: 1762:

Okunkova, Anna A.; Volosova, Marina A.; Hamdy, Khaled; Gkhashim, Khasan I. (February 2023).

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Han, F.; Chen, L.; Yu, D.; Zhou, X. (2006). "Basic study on pulse generator for micro-EDM".

539:–. This allows the wire-cut EDM to be programmed to cut very intricate and delicate shapes. 2503: 2390: 2296: 1995: 1623:

Stages to Saturn: A Technological History of the Apollo/Saturn Launch Vehicle (NASA-SP4206)

1567: 1529: 1491: 1432: 1231: 766: 97: 8: 2319: 2246: 2098: 662: 405: 165:

Commercial wire EDM capability and use has advanced substantially during recent decades.

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The erosive effect of electrical discharges was first noted in 1770 by English physicist

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Several manufacturers produce EDM machines for the specific purpose of removing broken

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Small hole EDM is also used to create microscopic orifices for fuel system components,

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A recast layer is formed at the cut surface due to melting of the material by the arc.

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Small hole EDM is used to drill rows of holes into the leading and trailing edges of

265: 226: 155: 2395: 2158: 2148: 2123: 2118: 1985: 1960: 1775: 1735: 1602: 1575: 1537: 1499: 1440: 1381: 1341: 1314: 1239: 1204: 1177: 735: 114: 1621: 943:"EDM Working Principle, Types, Process Parameters, Equipments, & Applications" 2093: 2028: 2023: 1843: 1780: 1763: 1739: 1688: 789: 277: 1836: 479:

The wire, which is constantly fed from a spool, is held between upper and lower

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Potential fire hazard associated with use of combustible oil based dielectrics.

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When the voltage between the two electrodes is increased, the intensity of the

30: 1853: 1713: 1385: 1107: 878:

Reproducing sharp corners on the workpiece is difficult due to electrode wear.

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EDM is often included in the "non-traditional" or "non-conventional" group of

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New Arc Detection Technology for Highly Efficient Electro-Discharge Machining

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The additional time and cost used for creating electrodes for ram/sinker EDM.

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plane. On most machines, the upper guide can also move independently in the

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Pipe or container internal contours and internal corners down to R 0.001".

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Dulebohn, "Tracer controlled machining by electrically induced erosion",

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an increased current research effort in related experimental techniques.

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Physico-mathematical analysis of the electro discharge machining process

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Koelsch, James (October 2009). "EDM: A Changing Competitive Calculus",

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guides which is centered in a water nozzle head. The guides, usually

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Sinker EDM allowed quick production of 614 uniform injectors for the

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There are also stand-alone small hole drilling EDM machines with an

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operations) to some hundreds of micrometers in roughing conditions.

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The EDM process is most widely used by the mold-making, tool, and

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rocket engine, six of which were needed for each trip to the moon.

150:

The wire-cut type of machine arose in the 1960s for making tools (

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Surf. Eng. Appl. Electrochem. (Elektronnaya Obrabotka Materialov)

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Surf. Eng. Appl. Electrochem. (Elektronnaya Obrabotka Materialov)

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Surf. Eng. Appl. Electrochem. (Elektronnaya Obrabotka Materialov)

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The International Journal of Advanced Manufacturing Technology

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Machining of extremely hard material to very close tolerances.

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Small hole drilling EDM is used in a variety of applications.

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in the volume between the electrodes becomes greater, causing

2400: 2013: 1761: 770: 473: 319: 242: 230: 229:. EDM can cut intricate contours or cavities in pre-hardened 181: 1519: 1481: 1037: 747:

parts eroded from them as needed and without pre-drilling.

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Characterization of electrical discharge machining plasmas

77:. One of the electrodes is called the tool, or simply the 896:

can be machined only with specific set-up of the process.

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A Practical Guide to Electro-Discharge Machining, 2nd ed

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accuracy will not be affected by heat treat distortion.

85:, while the other is called the workpiece-electrode, or 1087: 1655: 1653: 1651: 1649: 1647: 1595:

International Journal of Machine Tools and Manufacture

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with internal cooling as applied in the high-pressure

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Engineering Design For Electrical Discharge Machining

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Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994).

1331: 1644: 1415: 1221: 959: 922: 821:can improve the accuracy and reduce the tool costs 1619: 1073:(1st ed.). Industrial Press. p. 6.2.1. 796: 312:Therefore, wear is a major problem in that area. 2490: 1111:, filed 4 December 1969, issued 19 October 1971. 1686: 1553: 1551: 824: 1725: 1515: 1513: 1425:Journal of Micromechanics and Microengineering 1283: 1281: 1279: 1277: 1224:Journal of Micromechanics and Microengineering 1133: 1131: 1129: 249:. Also, applications of this process to shape 1926: 1888: 1477: 1475: 1371: 1264:McCarthy, Willard J. and McGeough, Joseph A. 1070:Exploring advanced manufacturing technologies 448:Electrical discharge erosion (Electric arc). 358: 1548: 1469:. PhD Thesis Katholieke Universiteit Leuven. 1416:Ferri, C.; Ivanov, A.; Petrelli, A. (2008). 1052:: CS1 maint: multiple names: authors list ( 1023:: CS1 maint: multiple names: authors list ( 993:: CS1 maint: multiple names: authors list ( 890:Excessive tool wear occurs during machining. 813: 546:as small as 0.021 mm (0.83 mils) using 272:, and opposite to the "conventional" group ( 1940: 1510: 1304: 1274: 1126: 624:. Unsourced material may be challenged and 472:, a thin single-strand metal wire, usually 1933: 1919: 1895: 1881: 1693:. Industrial Press Inc. pp. 175–179. 1592: 1472: 1307:Journal of Materials Processing Technology 1197:Journal of Materials Processing Technology 1067:Krar, Stephen F.; Gill, Arthur R. (2003). 320:Definition of the technological parameters 1779: 1194: 644:Learn how and when to remove this message 576: 1411: 1409: 1407: 1405: 1403: 1066: 881:Specific power consumption is very high. 734: 718: 705: 681: 436: 428: 392: 260:methods together with processes such as 180: 29: 1855:How these impossibly thin cuts are made 1805: 1690:Manufacturing Processes Reference Guide 1659: 1120: 1093: 965: 928: 656: 128:resistor–capacitor circuit (RC circuit) 14: 2491: 1170:CIRP Annals - Manufacturing Technology 1140:"The Remarkable Abilities of Wire EDM" 1137: 714: 1914: 1876: 1671: 1400: 894:Electrically non-conductive materials 866:Difficulty finding expert machinists. 677: 1714:ELECTRICAL DISCHARGE MACHINING (EDM) 1680: 1362:, Society of Manufacturing Engineers 784:axis also known as a super drill or 622:adding citations to reliable sources 589: 940: 462:wire electrical discharge machining 24: 1676:. Ateliers des Charmilles, Geneva. 1418:"Electrical measurements in µ-EDM" 1334:Journal of Manufacturing Processes 869:The slow rate of material removal. 73:liquid and subject to an electric 25: 2525: 1830: 739:Small hole drilling EDM machines. 1902: 1728:Machining Science and Technology 1209:10.1016/j.jmatprotec.2007.12.143 852:Very fine holes can be attained. 594: 1800: 1755: 1719: 1707: 1665: 1613: 1586: 1459: 1365: 1352: 1325: 1298: 1258: 1215: 1188: 1161: 585: 176: 145: 130:used to charge the electrodes. 120: 34:An electrical discharge machine 2192:Electrical discharge machining 1981:Numerical control (NC and CNC) 1809:Electrical Discharge Machining 1099: 1060: 1031: 1001: 971: 934: 862:Disadvantages of EDM include: 855:Tapered holes may be produced. 797:Metal disintegration machining 39:Electrical discharge machining 13: 1: 1607:10.1016/S0890-6955(98)00047-9 1445:10.1088/0960-1317/18/8/085007 1346:10.1016/S1526-6125(05)70084-0 1319:10.1016/S0924-0136(03)00748-9 1287:Descoeudres, Antoine (2006). 1182:10.1016/S0007-8506(07)63047-9 915: 833:. Advantages of EDM include: 769:for synthetic fibers such as 388: 1781:10.3390/technologies11010006 1740:10.1080/10910344.2010.500497 1626:. DIANE Publishing. p. 825:Advantages and disadvantages 18:Electric discharge machining 7: 2039:List of drill and tap sizes 1620:Bilstein, Roger E. (1999). 1244:10.1088/0960-1317/14/12/013 903: 690:, to give a curved surface. 670:, copper tungsten, or pure 424: 10: 2530: 2355:Magnetic switchable device 1560:Journal of Applied Physics 1522:Journal of Applied Physics 1484:Journal of Applied Physics 884:Power consumption is high. 773:, and other applications. 359:Material removal mechanism 253:tools have been reported. 173:can be finely controlled. 108: 2433: 2378: 2305: 2197:Electrochemical machining 2172: 2062: 1994: 1949: 1910: 1465:Van Dijck, Frans (1973). 1386:10.1007/s00170-006-0483-9 1360:Manufacturing Engineering 910:Electrochemical machining 831:electrochemical machining 829:EDM is often compared to 819:Closed-loop manufacturing 814:Closed-loop manufacturing 487:-controlled, move in the 262:electrochemical machining 27:Metal fabrication process 565:optimize the operation. 433:CNC Wire-cut EDM machine 383: 2514:Metallurgical processes 2277:Rotary transfer machine 2262:Photochemical machining 2202:Electron-beam machining 2164:Tool and cutter grinder 1806:Jameson, E. C. (2001). 1270:Encyclopædia Britannica 331:and the group based on 251:polycrystalline diamond 1138:Rogers, Barry (2018), 740: 732: 711: 691: 688:sinking (metalworking) 577:Fast hole drilling EDM 464:(WEDM), also known as 457: 452:Electrical potential. 434: 409: 221: 188:Pulse generator (DC). 35: 2473:Tools and terminology 1108:U.S. patent 3,614,372 738: 722: 709: 685: 440: 432: 403: 184: 98:dielectric break down 33: 2391:Machining vibrations 2297:Ultrasonic machining 887:"Overcut" is formed. 657:Prototype production 618:improve this section 335:-controlled pulses. 156:numerical controlled 2411:Tool and die making 2099:Cylindrical grinder 1572:1993JAP....73.7900E 1534:1989JAP....66.4104P 1496:1989JAP....66.4095D 1437:2008JMiMi..18h5007F 1236:2004JMiMi..14.1687M 715:Small hole drilling 169:have increased and 2079:Abrasive machining 1842:2019-02-03 at the 1672:Semon, G. (1975). 947:mechanicalsite.com 741: 733: 712: 692: 678:Coinage die making 458: 435: 410: 222: 200:dielectric fluid. 36: 2486: 2485: 2429: 2428: 1819:978-0-87263-521-0 1123:, pp. 12–17. 1096:, pp. 10–12. 983:. 1977, 3: 28–33. 941:Jaiswal, Vishal. 654: 653: 646: 401: 266:water jet cutting 160:David H. Dulebohn 69:, separated by a 45:), also known as 16:(Redirected from 2521: 2396:Speeds and feeds 2149:Sharpening stone 2124:Grinding machine 2119:Grinding dresser 1986:Stewart platform 1935: 1928: 1921: 1912: 1911: 1897: 1890: 1883: 1874: 1873: 1856: 1827: 1822:. Archived from 1794: 1793: 1783: 1759: 1753: 1751: 1723: 1717: 1711: 1705: 1704: 1684: 1678: 1677: 1669: 1663: 1657: 1642: 1641: 1617: 1611: 1610: 1590: 1584: 1583: 1580:10.1063/1.353942 1555: 1546: 1545: 1542:10.1063/1.343995 1517: 1508: 1507: 1504:10.1063/1.343994 1479: 1470: 1463: 1457: 1456: 1422: 1413: 1398: 1397: 1369: 1363: 1356: 1350: 1349: 1329: 1323: 1322: 1313:(1–3): 332–334. 1302: 1296: 1285: 1272: 1262: 1256: 1255: 1219: 1213: 1212: 1203:(1–3): 245–250. 1192: 1186: 1185: 1165: 1159: 1158: 1156: 1155: 1146:, archived from 1135: 1124: 1118: 1112: 1110: 1103: 1097: 1091: 1085: 1084: 1064: 1058: 1057: 1051: 1043: 1035: 1029: 1028: 1022: 1014: 1013:. 1979, 5: 8–13. 1005: 999: 998: 992: 984: 975: 969: 963: 957: 956: 954: 953: 938: 932: 926: 649: 642: 638: 635: 629: 598: 590: 402: 115:Joseph Priestley 21: 2529: 2528: 2524: 2523: 2522: 2520: 2519: 2518: 2489: 2488: 2487: 2482: 2425: 2374: 2301: 2168: 2159:Surface grinder 2094:Coated abrasive 2065: 2058: 2029:Drill bit sizes 2024:Drill bit shank 1999: 1990: 1952: 1945: 1939: 1906: 1901: 1870: 1854: 1844:Wayback Machine 1833: 1820: 1803: 1798: 1797: 1760: 1756: 1724: 1720: 1712: 1708: 1701: 1685: 1681: 1670: 1666: 1658: 1645: 1638: 1618: 1614: 1591: 1587: 1556: 1549: 1518: 1511: 1480: 1473: 1464: 1460: 1420: 1414: 1401: 1370: 1366: 1357: 1353: 1330: 1326: 1303: 1299: 1286: 1275: 1263: 1259: 1220: 1216: 1193: 1189: 1166: 1162: 1153: 1151: 1136: 1127: 1119: 1115: 1106: 1104: 1100: 1092: 1088: 1081: 1065: 1061: 1045: 1044: 1042:. 1980, 1: 5–8. 1036: 1032: 1016: 1015: 1006: 1002: 986: 985: 976: 972: 964: 960: 951: 949: 939: 935: 927: 923: 918: 906: 827: 816: 799: 790:deionized water 717: 680: 659: 650: 639: 633: 630: 615: 599: 588: 579: 427: 393: 391: 386: 361: 322: 179: 148: 123: 111: 47:spark machining 28: 23: 22: 15: 12: 11: 5: 2527: 2517: 2516: 2511: 2506: 2501: 2484: 2483: 2481: 2480: 2475: 2470: 2465: 2460: 2455: 2450: 2445: 2440: 2434: 2431: 2430: 2427: 2426: 2424: 2423: 2418: 2413: 2408: 2403: 2398: 2393: 2388: 2382: 2380: 2376: 2375: 2373: 2372: 2367: 2362: 2357: 2352: 2347: 2342: 2337: 2332: 2327: 2322: 2317: 2311: 2309: 2303: 2302: 2300: 2299: 2294: 2289: 2284: 2279: 2274: 2269: 2264: 2259: 2254: 2252:Milling cutter 2249: 2244: 2239: 2234: 2229: 2224: 2219: 2214: 2209: 2204: 2199: 2194: 2189: 2184: 2178: 2176: 2170: 2169: 2167: 2166: 2161: 2156: 2151: 2146: 2141: 2136: 2131: 2129:Grinding wheel 2126: 2121: 2116: 2111: 2106: 2101: 2096: 2091: 2086: 2081: 2076: 2070: 2068: 2060: 2059: 2057: 2056: 2051: 2046: 2041: 2036: 2031: 2026: 2021: 2016: 2011: 2005: 2003: 1992: 1991: 1989: 1988: 1983: 1978: 1973: 1968: 1963: 1957: 1955: 1951:Computer-aided 1947: 1946: 1938: 1937: 1930: 1923: 1915: 1908: 1907: 1900: 1899: 1892: 1885: 1877: 1868: 1867: 1851: 1846: 1832: 1831:External links 1829: 1826:on 2011-09-28. 1818: 1802: 1799: 1796: 1795: 1754: 1718: 1706: 1699: 1679: 1664: 1643: 1636: 1612: 1585: 1547: 1509: 1471: 1458: 1399: 1364: 1351: 1324: 1297: 1273: 1266:"Machine tool" 1257: 1214: 1187: 1160: 1125: 1113: 1098: 1086: 1079: 1059: 1030: 1000: 970: 958: 933: 920: 919: 917: 914: 913: 912: 905: 902: 901: 900: 897: 891: 888: 885: 882: 879: 876: 873: 870: 867: 860: 859: 856: 853: 850: 847: 844: 841: 838: 826: 823: 815: 812: 798: 795: 760:single crystal 752:turbine blades 716: 713: 679: 676: 658: 655: 652: 651: 602: 600: 593: 587: 584: 578: 575: 556:PID controlled 426: 423: 390: 387: 385: 382: 360: 357: 321: 318: 178: 175: 171:surface finish 147: 144: 122: 119: 110: 107: 104: 94:electric field 88: 84: 80: 26: 9: 6: 4: 3: 2: 2526: 2515: 2512: 2510: 2507: 2505: 2502: 2500: 2499:Electric arcs 2497: 2496: 2494: 2479: 2476: 2474: 2471: 2469: 2466: 2464: 2461: 2459: 2456: 2454: 2451: 2449: 2446: 2444: 2441: 2439: 2436: 2435: 2432: 2422: 2419: 2417: 2414: 2412: 2409: 2407: 2404: 2402: 2399: 2397: 2394: 2392: 2389: 2387: 2386:Cutting fluid 2384: 2383: 2381: 2377: 2371: 2368: 2366: 2363: 2361: 2358: 2356: 2353: 2351: 2350:Machine taper 2348: 2346: 2343: 2341: 2338: 2336: 2335:Indexing head 2333: 2331: 2328: 2326: 2323: 2321: 2318: 2316: 2313: 2312: 2310: 2308: 2307:Machine tools 2304: 2298: 2295: 2293: 2290: 2288: 2285: 2283: 2280: 2278: 2275: 2273: 2270: 2268: 2265: 2263: 2260: 2258: 2255: 2253: 2250: 2248: 2245: 2243: 2240: 2238: 2235: 2233: 2230: 2228: 2225: 2223: 2220: 2218: 2215: 2213: 2210: 2208: 2205: 2203: 2200: 2198: 2195: 2193: 2190: 2188: 2185: 2183: 2180: 2179: 2177: 2175: 2171: 2165: 2162: 2160: 2157: 2155: 2154:Spark testing 2152: 2150: 2147: 2145: 2142: 2140: 2137: 2135: 2132: 2130: 2127: 2125: 2122: 2120: 2117: 2115: 2112: 2110: 2109:Flick grinder 2107: 2105: 2104:Diamond plate 2102: 2100: 2097: 2095: 2092: 2090: 2089:Bench grinder 2087: 2085: 2084:Angle grinder 2082: 2080: 2077: 2075: 2072: 2071: 2069: 2067: 2061: 2055: 2052: 2050: 2047: 2045: 2042: 2040: 2037: 2035: 2032: 2030: 2027: 2025: 2022: 2020: 2017: 2015: 2012: 2010: 2007: 2006: 2004: 2002: 1997: 1993: 1987: 1984: 1982: 1979: 1977: 1974: 1972: 1969: 1967: 1964: 1962: 1959: 1958: 1956: 1954: 1948: 1944:and computing 1943: 1936: 1931: 1929: 1924: 1922: 1917: 1916: 1913: 1909: 1905: 1898: 1893: 1891: 1886: 1884: 1879: 1878: 1875: 1871: 1865: 1861: 1857: 1852: 1850: 1847: 1845: 1841: 1838: 1835: 1834: 1828: 1825: 1821: 1815: 1811: 1810: 1791: 1787: 1782: 1777: 1773: 1769: 1765: 1758: 1749: 1745: 1741: 1737: 1733: 1729: 1722: 1715: 1710: 1702: 1700:0-8311-3049-0 1696: 1692: 1691: 1683: 1675: 1668: 1661: 1656: 1654: 1652: 1650: 1648: 1639: 1637:9780788181863 1633: 1629: 1625: 1624: 1616: 1608: 1604: 1600: 1596: 1589: 1581: 1577: 1573: 1569: 1565: 1561: 1554: 1552: 1543: 1539: 1535: 1531: 1527: 1523: 1516: 1514: 1505: 1501: 1497: 1493: 1489: 1485: 1478: 1476: 1468: 1462: 1454: 1450: 1446: 1442: 1438: 1434: 1431:(8): 085007. 1430: 1426: 1419: 1412: 1410: 1408: 1406: 1404: 1395: 1391: 1387: 1383: 1379: 1375: 1368: 1361: 1355: 1347: 1343: 1339: 1335: 1328: 1320: 1316: 1312: 1308: 1301: 1294: 1290: 1284: 1282: 1280: 1278: 1271: 1267: 1261: 1253: 1249: 1245: 1241: 1237: 1233: 1229: 1225: 1218: 1210: 1206: 1202: 1198: 1191: 1183: 1179: 1175: 1171: 1164: 1150:on 2018-05-22 1149: 1145: 1141: 1134: 1132: 1130: 1122: 1117: 1109: 1102: 1095: 1090: 1082: 1076: 1072: 1071: 1063: 1055: 1049: 1041: 1034: 1026: 1020: 1012: 1004: 996: 990: 982: 974: 967: 962: 948: 944: 937: 930: 925: 921: 911: 908: 907: 898: 895: 892: 889: 886: 883: 880: 877: 874: 871: 868: 865: 864: 863: 857: 854: 851: 848: 845: 842: 839: 836: 835: 834: 832: 822: 820: 811: 808: 804: 803:cutting tools 794: 791: 787: 783: 779: 774: 772: 768: 763: 761: 757: 753: 748: 744: 737: 730: 726: 725:turbine blade 721: 708: 704: 701: 697: 689: 684: 675: 673: 669: 664: 648: 645: 637: 634:November 2017 627: 623: 619: 613: 612: 608: 603:This section 601: 597: 592: 591: 583: 574: 570: 566: 562: 560: 557: 552: 549: 545: 540: 538: 534: 530: 526: 522: 518: 514: 510: 506: 502: 498: 494: 490: 486: 482: 477: 475: 471: 467: 463: 455: 451: 447: 443: 439: 431: 422: 418: 414: 407: 381: 377: 373: 369: 365: 356: 353: 348: 344: 340: 336: 334: 330: 325: 317: 313: 309: 305: 301: 299: 293: 289: 287: 283: 279: 275: 271: 270:laser cutting 267: 263: 259: 254: 252: 248: 244: 240: 236: 232: 228: 219: 215: 212:Tool holder. 211: 207: 203: 199: 195: 191: 187: 183: 174: 172: 168: 163: 161: 157: 153: 143: 141: 137: 131: 129: 118: 116: 106: 102: 99: 95: 90: 86: 82: 78: 76: 72: 68: 64: 60: 56: 52: 51:spark eroding 48: 44: 40: 32: 19: 2365:Rotary table 2345:Lathe center 2232:Machine tool 2191: 2064:Grinding and 1904:Metalworking 1869: 1824:the original 1808: 1804: 1801:Bibliography 1771: 1768:Technologies 1767: 1757: 1731: 1727: 1721: 1716:. header.com 1709: 1689: 1682: 1673: 1667: 1660:Jameson 2001 1622: 1615: 1598: 1594: 1588: 1566:(11): 7900. 1563: 1559: 1525: 1521: 1487: 1483: 1466: 1461: 1428: 1424: 1380:(5–6): 474. 1377: 1373: 1367: 1359: 1354: 1337: 1333: 1327: 1310: 1306: 1300: 1292: 1269: 1260: 1230:(12): 1687. 1227: 1223: 1217: 1200: 1196: 1190: 1173: 1169: 1163: 1152:, retrieved 1148:the original 1143: 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Retrieved 946: 936: 931:, p. 1. 929:Jameson 2001 924: 861: 828: 817: 800: 785: 781: 777: 775: 764: 749: 745: 742: 693: 660: 640: 631: 616:Please help 604: 586:Applications 580: 571: 567: 563: 553: 543: 541: 536: 532: 528: 524: 520: 516: 512: 508: 504: 500: 496: 492: 488: 478: 470:wire cutting 469: 466:wire-cut EDM 465: 461: 459: 453: 449: 445: 441: 419: 415: 411: 378: 374: 370: 366: 362: 351: 349: 345: 341: 337: 326: 323: 314: 310: 306: 302: 294: 290: 255: 223: 217: 213: 209: 205: 201: 197: 193: 189: 185: 177:Generalities 164: 149: 146:Wire-cut EDM 132: 124: 121:Die-sink EDM 112: 91: 63:wire erosion 62: 59:wire burning 58: 54: 50: 46: 42: 38: 37: 2504:Hole making 2443:Fabrication 2379:Terminology 2315:Angle plate 2242:Metal lathe 2134:Jig grinder 2044:Tap and die 1953:engineering 1864:Steve Mould 1528:(9): 4104. 1490:(9): 4095. 1176:: 201–204. 786:hole popper 756:jet engines 700:drop hammer 696:pancake die 329:RC circuits 268:(WJ, AWJ), 225:insulating 192:Workpiece. 140:vacuum tube 136:interrupter 55:die sinking 2493:Categories 2463:Metallurgy 2257:Pantograph 2049:Tap wrench 1866:(Apr 2023) 1734:(2): 189. 1601:(4): 669. 1295:, no 3542. 1293:Thèse EPFL 1154:2018-05-21 1080:0831131500 952:2023-08-25 916:References 767:spinnerets 559:de-ionizer 389:Sinker EDM 333:transistor 167:Feed rates 87:work piece 71:dielectric 67:electrodes 2509:Machining 2458:Machining 2453:Jewellery 2421:Workpiece 2416:Tramp oil 2406:Tolerance 2237:Machining 2227:Jig borer 2212:Engraving 2187:Broaching 2174:Machining 2054:Threading 2019:Drill bit 2001:threading 1942:Machining 1790:2227-7080 1748:138552270 1453:110495415 1394:110776709 1340:: 75–82. 1252:250921623 807:fasteners 605:does not 456:Workpiece 298:micro-EDM 258:machining 239:hastelloy 196:Fixture. 83:electrode 2468:Smithing 2207:End mill 2114:Grinding 2074:Abrasive 2034:Drilling 2009:Die head 1996:Drilling 1840:Archived 1774:(1): 6. 1144:TechSpex 904:See also 754:used in 668:graphite 425:Wire EDM 286:drilling 282:grinding 235:titanium 227:ceramics 208:Filter. 103:flushing 2478:Welding 2448:Forming 2438:Casting 2370:Wiggler 2360:Mandrel 2330:Fixture 2292:Turning 2287:Skiving 2247:Milling 2222:Hobbing 2144:Sanding 2139:Lapping 2066:lapping 1860:YouTube 1812:. 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