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At the 5 o'clock position on both of those holes it looks like the OEM use a punch to move the material enough to retain them.

I was going to reply with the same points tdmidget pointed out. Perhaps if the hole you burn through is large enough you'll be able to break the ball up and pull the pieces out.

A company I worked at sold a few different machines for the nozzle holes. Some of the machines south of the border are acid drills and others we made were EDM.

My point was more to point out that hard and fast rules aren't always followed or true. I'm definitely pedantic. Pedant wasn't a word I ever expected to see on this forum, even with as many of us...

Except for those pesky machines that can rotate the head, right? If I rotate my B-Axis the spindle axis is not perpendicular to the X-Y plane, but the Z-Axis still is.

I mean if it was me I would use go/no go pin gages at the drawing tolerance sizes and a bore gage to make sure there isn't any taper or a barrel shape. If you know your customer expects to use the...

I'm not familiar with Makino, but I assume there are upper and lower contacts. If it is breaking above the part, I would look at the lower contacts and/or cables. Think of the wire as a fuse that...

Every CNC machine I've been on already has a key used to access the controller/drives/etc enclosure with a purpose built bottle opener. Even our CMM has one, Hexagon must know they drive people to...

I know this won't help, but the last time I had to drill a 1/4" hole through a bolt I put in a 6mm electrode, picked up on the end of the bolt with the electrode, cranked up the settings, started it...

For a while it seemed like every time we shut down some of our older Sodick WEDM machines for a long weekend or shutdown to 'save the company money' we ended up with a good chance the computer...

The one benefit I think the end users see from prusa using so many 3d printed parts is they have 600 machines running prints 24hrs a day, which means they have lots of opportunity to see problems...

I think that most any machine you run 480V to you can just run an ethernet cable to or fiber to, so no one really does it. I can get behind not wanting to pull another cable in an already installed...

Assuming it is a 3phase 480v system check out what this company did: https://www.egauge.net/docs/277v-hpt-manual.pdf

The important part is the lower half of page 5. It looks like you can use a...

I found it! We used Net-Inspect. Supply Chain Management and Quality Management Software | Net-Inspect

We started off using it for AS9102 First Articles, then for measurement collection and SPC,...

Electronic micrometers, calipers, depth gages etc can be connected to the computer either by USB or wireless. Hit one button and the number is entered for you without risk of a typo. Electronic...

You mean like Alnico? :D Alnico - Wikipedia

If you are removing .01" or more, you should be removing all of the recast and remelt layers of any EDM process. Your etching process after the polishing should remove a tiny bit more as well. Since...

That Elox setup was pretty unique and was setup by the guy who I learned EDM from. The part was ring shaped and all of the holes were about 10 degrees off axis to the Z. That is they were in a cone...

This is true and typically I have seen qualification spheres at Ø.750 or larger.

The error you see when the probe direction does not match the surface you are checking is called cosine error and...

The size of the qualification sphere is pretty irrelevant. The qualification sphere is telling the CMM where your current tip is in relation to the first calibrated tip, it also tells the CMM the...

Another thought: If this is a repeat job, and the holes are a consistent pattern, die sinking it with a multi electrode holder can be faster so long as you can get the flush where it is needed. ...

You can make an entire career on EDM hole drilling quite easily, there are 30+Million cooling holes in a modern gas turbine. I'll try to answer your questions in the same order you gave them. There...

I think the others don't see the value in collecting an analyzing data that the machines already produce. In the past I did long term monitoring on our CNC EDM machines in house and we knew that...

That wouldn't have worked at my last shop. We were adding 200 gallons of coolant a day! We had a mixer that pulled coolant from a 55 gallon barrel on wheels with a hose that fed it from a spigot on...