Hi sharpe428:
Those look mostly like slugs from extrusion dies to me.
Are they tight tolerance throughout the whole profile or just at the business end of the die?
Looks like you've got some pretty big tapers too; what machine are they cut on?
I sure couldn't cut something like that on my Sodick...10 degrees is about maximum before I run out of UV travel and the flushing bogs down.
Very cool stuff.
Cheers

Marcus
www.implant-mechanix.com

.004" across the flats on the small end, .008 across the flats on the large end. Sorry for the large pic, but this is so small it needs the large pic to see the detail.



TMD

Not really...about half that size would be better and would show detail just fine. Was this for an order or just to see if you could do it ?

TMD,

Wow! How the heck do you find the part after it drops out??

Hi implex,

Yes most of that work is extrusion dies,taper upto 45 deg.on mitsubishi cx-20 with an extended U-V travel of 3.00" per side.
The most difficult work shown there is the pics in the second row down,1st 2 pics.The round disk w/dime.They were hole popped at compound angles with an .012" trode and did NOT short out the .010" wire threaded (by hand) at that compound angle.To a lesser difficulty,look at row1 last 4 pics,rows2&3 last pic they are single angle starts(iI tried to set the slugs just as they had come out of the part.
Check out pics 3,4&5 of row 3.Top shape was a "bowtie" approx 1.600" X .070" and bottom was a 1.000" diam,had to come out in three pcs.My coolest ever (for me) was a simple "U" shape 1.5" X1.5" with barb type things all over it,on top, and a 1.00" diam. on bottom.It had to come out in 18 separate slugs.
Thanks for looking

Just to see what was possible on my machine.. will try to make the pic smaller TMD

Precision Metal..

I lost the first couple so decided not to cut it free... this is impossible to find after cut off.

I have since installed a fine mesh screen below the lower nozzle to catch this stuff. There seems to be more of it coming along lately.

TMD

Ah, much better thanks TMD !

What machine and wire size?

Hi TMD:
I had success with a part just a little bit bigger than this one by tethering it to a spring with fine copper wire.
I was finding that the extremely small part would fold inward toward the wire during cutoff and would get gouged by the wire.
Tethering it to a spring pulled it away from the hot wire and allowed me to retrieve it easily.
Dressing off the stub under the scope was a pain though...I had to stick it onto a carrier block with melted wax and then dress the stub with a diamond file.
Here's a link:
http://implant-mechanix.com/?cat=24
Cheers

Marcus
www.implant-mechanix.com

I'll toss one in here as well... like Brian's example, this one I designed as a show demo for Makino. This demo is a reuleaux triangle (tri-lobe) consisting of three pieces of identical geometry which when interlocked have a measurement of .99995" across any point, inserted into a window of 1.0000" square with elliptical corners. When turned within the window, and depending upon its orientation, the tri-lobe will be in full contact with between 3 and 5 points inside the window.

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KilrB,

This was done on an Agie Vertex, .00078 wire dia. (20um)

TMD

... and I hate using .004" ...

How do you even handle that?

The sensitivity of the machine to handle the small wire has a lot to do with the ease of handling it. I really do not have a problem handling the wire and getting it loaded on the machine. Once on the machine it is a no brainer. No more trouble than large (.002) wire. I was cutting with .002 wire today and it seemed like this wire was huge. I have not run any wire larger than .004 for years.

TMD

this is all impressive!
hopefully one day i'll be cool enough to join the edm gang!

Here is a TMD designed and built precision Kantwist clamp with additional reach for use in catching drops on my edm. It has 1.5 inch jaw opening and jaws are cut different on all 4 sides. V grooves on 3 sides, flat on the other side. V grooves (2 sizes) running the long way on jaws, one running perpendicular to jaws for various angles of round stock. This can be held in the 3R super vise for compound angle stuff. This is all 303 and 304 stainless.

TMD

Misc. parts from over the years.

ps know of any EDM machinist jobs in the TN area? 25+ years experience.

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Is that t rex one piece? Got any up close pics of it? Looks pretty cool.

It's a lot of little pieces put together like a 3D puzzle.

MMS TN

Looks like someone is off their rocker ! hee hee..

TMD