Operating Procedures and Safety Precautions for EDM Wire Erosion
EDM wire erosion is a high-precision metal machining technology that removes material through continuous electrical discharges. It is commonly used in mold making and for cutting complex parts, especially hard conductive materials.
一.Operating Procedure
1.Preparations
(1) Prepare the workpiece and the electrode. Select appropriate materials for both the workpiece and the electrode based on the machining requirements.
(2) Install the electrode and the workpiece. Mount them on the worktable of the EDM machine, ensuring they are correctly positioned.
(3) Clean the work area. Before starting the machining process, clean the work area thoroughly to ensure a tidy environment and prevent interference from dust or debris.
2.Machine start-up operation
(1) Check the power supply. Ensure that the power switch of the EDM machine is turned off, the plug is properly inserted, and the power cable is connected.
(2) Turn on the ventilation system. Before starting the EDM machine, make sure the ventilation system is functioning properly.
(3) Switch on the power. Turn on the power switch of the EDM machine and wait for it to complete the self-check process.
3.Program settings
(1) Select the appropriate program. Based on the machining requirements, choose the correct program on the EDM machine interface, or write your own program.
(2) Set the machining speed. Adjust the machining speed according to the workpiece material and processing requirements.
(3) Set the machining depth. Set the appropriate machining depth based on the size, shape, and processing requirements of the workpiece.
4.Machining Process
(1) Manually align the electrode and workpiece. To ensure precision and effectiveness, manual alignment is required.
(2) Start machining. Press the start button on the EDM machine and wait for the machining to finish.
(3) Monitor the machining process. During machining, regularly observe the condition of the electrode and workpiece to ensure the process runs smoothly.
5.Shutdown Procedure
(1) Stop machining. After machining is complete, press the stop button to halt the operation.
(2) Turn off the power switch. Turn off the power switch of the EDM machine and disconnect the power cable to ensure the machine is safely powered down.
(3) Clean the work area. After machining is finished, remove the workpiece and electrode, and clean the work area thoroughly.
二.Safety Precautions
Operators must undergo professional training, pass examinations, and be certified before operating the machine independently.
Open flames and smoking are strictly prohibited in the operation room. Foam or powder fire extinguishers suitable for oil fires must be available.
During operation, ensure that all machinery, pulse power supply, control knobs, display instruments, and exhaust fans are in good working condition.
The pulse power supply must be turned off when loading or unloading workpieces, positioning, aligning electrodes, or cleaning the machine.
The working fluid level should be maintained at 50–60 mm above the surface of the workpiece to prevent fire due to low fluid level.
Do not touch the electrode with your hands. Operators must stand on insulated rubber mats or wooden platforms.
Harmful gases generated during machining must be promptly removed. If the exhaust fan malfunctions, appropriate measures must be taken or work must be stopped.
Regularly inspect and clean the filter in the working fluid tank to prevent clogging by iron debris or sludge. Ensure that the working fluid pump is in good condition, with clear sound and low noise. Address any issues promptly.
三.Machine Maintenance Rules
1.Add lubricating oil to the main working parts of the machine tool every week.
2.Clean the machine tool thoroughly every Saturday according to the specified guidelines.
3.It is strictly forbidden to place cloth scraps or debris on the EDM machine workbench. Keep the machine casing clean every day.
4.Check the machine's precision every month to ensure it meets the required standards, and check if the electrical box exhaust fan is functioning properly.
5.If any abnormal machine operation is found during work, stop using the machine immediately and report it to the supervisor for maintenance arrangements.
6.Check the machine for oil leaks regularly every week.
7.Inspect the electrical wiring weekly to ensure it is not damaged or detached. In case of any faults, immediately cut off the power supply and notify a professional electrician for repair. Non-professional personnel should not attempt to fix it themselves.
四.Machining Characteristics
The high energy density of pulse discharge makes it easier to machine special materials and complex-shaped workpieces that are difficult or impossible to process using conventional machining methods. It is not affected by material hardness or heat treatment conditions.
The pulse discharge duration in EDM is extremely short, and the heat generated during discharge has a very limited conduction and diffusion range, resulting in minimal heat-affected zones on the material.
During EDM machining, the tool electrode does not come into contact with the workpiece material, and the macroscopic force between the two is minimal. Therefore, the tool electrode does not need to be harder than the workpiece material, making electrode fabrication easier.
4.It can help redesign the structure of workpieces, simplify the machining process, extend the service life of parts, and reduce labor intensity. Based on these characteristics, the main applications of EDM machining include:
(1)Manufacturing punching dies, plastic molds, forging dies, and die-casting molds.
(2)Machining small holes, irregularly shaped holes, and threading holes in hard alloys.
(3)Cutting parts out of metal sheets.
(4)Machining narrow slots.