Belmont SY2535 EDM Drill

Ok running a Belmont SY2535 EDM Drill. The recommended settings, and all trial adjustments, for a 2.5mm electrode cutting 6061 aluminum to a thru depth at 9 inches, are apparently not applicable or is this just to deep for an electrode? any suggestions on the settings?

Hi dthrash22:
I am guessing you cannot get all the way to depth before the burn stalls.
If it starts out burning well and then quits after you're in a couple of inches, the most likely culprit is you've oxidized the aluminum in the hole to the point where it's non-conductive.
Once that oxide layer builds up enough, the burn quits because you've effectively built up a little insulating ceramic condom on the inside of the hole and the sparks can no longer get from the trode to the workpiece.

This is a fundamental characteristic of EDM work on aluminum and is made much worse by using a water dielectric because of course, water dissociates to hydrogen and oxygen.

The other issue of course, is that typical tube electrodes are not long enough to give you a 9" burn because so much is consumed during a burn.
A new electrode down an existing hole is always a bit of a PITA, especially as it gets near the bottom of the hole where the trode wear has made the hole bullet shaped.

Good luck with it; it's going to be a bitch for sure!
Cheers

Marcus
Implant Mechanix • Design & Innovation > HOME
www.vancouverwireedm.com

Yea, don't envy you that. Hole popping aluminum is a real bastard. Sorry!

Can you flip the part over and burn from the other side?
Works for me.

Regards,
John