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Newer then a Newbie to EDM looking for Ballpark starting place.

SIM

Titanium
Joined
Feb 19, 2004
Location
Staten Island NewYork USA
Machining, CNC milling/turning machining is my bag.

I have been getting a good amount of work that needs a saw cut.
For awhile we did just that, brought over to DoAll bandsaw followed an engraved line and cut.
That morphed into 1/16" saw cuts...so in CNC mill we started using slotting saws, jewelers saws and that was good.

Then it was .051 and then to .04...now I am breaking saws and screwing up arbors like I want to personally keep these people in business.

Has to be a better way. Got to thinking maybe EDM.

Parts come in various sizes and materials but to keep simple-


What would I need to make a straight .02-.04 slot in 1" CRS, Alum and SS.
Slot alignment is not critical, slots are straight and thru with a beginning and end opening.

Wondering cost of a machine, new used...brands to look for, stay away from. What items are needed, fluids, consumables...draw alot of current?
Cost of...disposal. Learning curve?

How long would I expect it to take to cut a slot 1" long in 1" CRS material, Alum?

Or maybe there is a better way then this...

Thanks for any and all input...this is my starting somewhere place.
 
Machining, CNC milling/turning machining is my bag.

I have been getting a good amount of work that needs a saw cut.
For awhile we did just that, brought over to DoAll bandsaw followed an engraved line and cut.
That morphed into 1/16" saw cuts...so in CNC mill we started using slotting saws, jewelers saws and that was good.

Then it was .051 and then to .04...now I am breaking saws and screwing up arbors like I want to personally keep these people in business.

Has to be a better way. Got to thinking maybe EDM.

Parts come in various sizes and materials but to keep simple-


What would I need to make a straight .02-.04 slot in 1" CRS, Alum and SS.
Slot alignment is not critical, slots are straight and thru with a beginning and end opening.

Wondering cost of a machine, new used...brands to look for, stay away from. What items are needed, fluids, consumables...draw alot of current?
Cost of...disposal. Learning curve?

How long would I expect it to take to cut a slot 1" long in 1" CRS material, Alum?

Or maybe there is a better way then this...

Thanks for any and all input...this is my starting somewhere place.


If you do a search on this forum you will find a lot of info. I just went through this same thing and learned a lot. For now I said "screw it" and am sending it out. But maybe another year and Ill be back looking for punishment again, Good Luck.

BTW I hear ya on those slotting saws, man I hate them Fn things.
 
Last edited:
Hello,

I am a newbie, but I will share what I know.

You will be able to cut your slots without much problem.

Wire EDM cutting speeds are calculated by the square inch.

For steel one inch thick, speed varies from 5 square inches per minute,
for a really old machine, to the mid thirties, for a modern machine.

Aluminum cuts much much faster. Wire EDM is a thermal process and Aluminum
has a low melting temperature, so it cuts quite fast.

You need to do some reading about EDM so you know more about the process
and it's issues, like recast. If recast will be an issue for you you will
need a more modern machine that has an AC, non-electrolytic power supply.

Wire EDM cost from $5 to $20 per hour to use, depending on the type of wire used.
The less expensive brass wire will most likely do what you want to do.

There are two methods of applying the deionized (DI) water, high pressure
jets or submerged in DI water. If you do complicated tall parts with voids
you will be better served with a submerged machine. The secret of any EDM
process is flushing, flushing, flushing............

Wire EDM requires a very good maintenance program, with weekly attention.

Cost of machines depends on what your needs are. Most machines in good
condition will easily cut in the .0001's and are very accurate machines.

Cost can vary from $20,000 to several hundred thousands of dollars. You can
buy much older machines for $10,000, but you will regret it because of the
costs incurred trying to keep it running.

Only buy a machine that you can get good support for. Some manufactures want
you to carry a support contract before they will even talk to you like
Mitsubishi ($2500/yr) or some will not charge you at all like Charmilles.
If you can, get a machine with local support.

I wouldn't buy a machine older than 1996, but if you have the work that will
pay for it I would buy a newer machine in the 2000's. New machines have better
auto threaders and better AC power supplies and cut faster and will be more
reliable.

There can be a significant learning curve, so you may want training.

Then there is the issue of what CAD/CAM system to buy and it's learning
curve. Since you already use CAD/CAM for your other CNC machines
learning may not be an issue for you, and you may be able to get a
wire EDM module for your current programming system.

Then there is the issue of tooling. Since wire EDM can be very precise
the tooling is very precise and VERY expensive. You can easily spend
$10,000 or $20,000 on tooling if no tooling comes with the machine.
DI water is very corrosive so all the tooling is made out of hardened
stainless steel.

So those are just a few issues. Do you homework. Don't just buy a machine
without knowing what your getting into. Buying a wire EDM is not like buying
a mill or lathe. There are several good books on EDM and wire EDM. Bud Guitrau's,
EDM Handbook is a good first start.

Good Luck,

Paul Hoffman
 
Machining, CNC milling/turning machining is my bag.



What would I need to make a straight .02-.04 slot in 1" CRS, Alum and SS.
Slot alignment is not critical, slots are straight and thru with a beginning and end opening.

.

...ummm...slot width is .02-.04 ???

.....and the slot depth is ????
 
Hello,

I am a newbie, but I will share what I know.



So those are just a few issues. Do you homework. Don't just buy a machine
without knowing what your getting into. Buying a wire EDM is not like buying
a mill or lathe. There are several good books on EDM and wire EDM. Bud Guitrau's,
EDM Handbook is a good first start.

Good Luck,

Paul Hoffman



Thank you Paul.
I have been reading quite a bit on these machines and you answered a majority of the questions I had.


Seeming to be machines are more then what I need and can justify for a single linear cut. Straight, narrow, clean cuts is what I need, If it was .01 to the left or right of my mark, nobody would care. I was hoping they had something like a mill with autofeed. Fixture part, lock, start feed and when it hit the set stop shut down.

If I have enough parts to do at one time, I'd sub it out...


Appreciate the help...this will help narrow down my search.
 
I you're looking for slightly used you might check with Milacron and/or EDM Network.

A used Brother HS-50/70A would be a good fit, but service and parts are becoming a problem.

If you're looking for new ask EDM Network about their Chmer line. Never ran one but keep hearing good about 'em.
 
1" cold rolled I would go with a current heavy setting, mitz uses epacks so i would use 1271 and .012 wire crank the voltage up to 80 and wire feed to 10 or 12, keep the adaptive control off and run at around .1 ipm maybe faster if it would allow it. Aluminum could probably double or triple that. Stainless would be about the same as steel.

Figure I cut 17-4 over 3" doc at .06 ipm with the above settings, 1/2 inch I've gone as high as .625 ipm...1/2" aluminum I've pushed over 1 ipm...1 ipm in wire edm is like high speed machining lolol.
 
HAVE A NICE
1993 Chevalier Sinker EDM—$6,900.00(EDM)
RAM TYPE (SINKERS)
Chevalier #ED-252
Ram type EDM 11.5″X, 7.9″Y Gromax Prog.Orbitor
ANY QUESTIONS: CALL 877-687-3188Used-Chevalier-EDM.jpg
 








 
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