Electro Discharge Ltd
Electro-Discharge Ltd was founded in 1980 to provide a specialist sub-contract Wire and Spark erosion service to the engineering industry. Our customer base is the whole of the UK, we also export our services to the international market.
WE ARE SPECIALISTS IN THE PRODUCTION OF COMPLEX PARTS THAT ARE DIFFICULT TO PRODUCE USING CONVENTIONAL CUTTING TOOLS.
Our quality system is NADCAP Accredited to AS7116, AS9100 REV:C, ISO 9001-2008 and Rolls-Royce SABRe9000. We utilise the latest solid works, CATIA5, and PEPS programming software, programs/drawings can be emailed in IGES or DXF formats so that the exact sizes can be obtained.
STANDARD & CNC EDM FACILITY
WIRE EDM FACILITY
FAST HOLE EDM DRILLING
Our plant list will provide you with a cross-section of our current machining capacity
EDM Wire Cutting or Wire Erosion uses a metallic wire to cut a programmed contour in a workpiece.
Extrusion dies, blanking punches and various other forms of jigs and fixtures are often machined by wire cutting. Cutting is always through the entire workpiece.
To start machining it is first necessary to drill a hole in the workpiece or start from the edge. On the machining area, each discharge creates a crater in the workpiece and an impact on the tool.
The wire can be inclined, thus making it possible to make parts with taper or with different profiles at the top and bottom. There is never any mechanical contact between the electrode and workpiece.
The Wire Cutting / Wire Erosion process takes place quickly—hundreds of thousands of sparks per second—but the wire never touches the workpiece.
The spark erosion occurs along the entire length of the wire adjacent to the workpiece, so the result is a part with an excellent surface finish and no burrs regardless of how large or small the cut.
Wire Cutting / Wire Erosion Process benefits:
* Low work holding forces
* Low cutting forces
* Very accurate process tolerances held +/- 0.0001"
* Complex profile capability
* Automatic wire threading allows for unmanned running of the machine.
* Hardened materials are easily machined
* Small corners, narrow slots
Spark Erosion machining is a method used when machining intricate detailed pieces.
The process involves both the workpiece and the tool being connected to a direct current, this provides a constant spark between the two.
Where the spark contacts the surface of the workpiece, it is heated to an extremely high temperature. The molten metal on the surface of the workpiece evaporates creating a crater. Continual discharge creates multiple craters, constantly eroding the workpiece to the desired finish.
The workpiece and the electrode are divided by a gap which is occupied by a synthetic insulating fluid.
The liquid allows for eroded debris to be washed away from the work area. The synthetic fluid is used to control the temperature of the process, by eliminating heat to the surrounding area the process results in no distortion or change in temper.
The process is suited for manufacturing intricate or short run parts and it can also be used for the refurbishment of existing damaged parts.
Sinker EDM, employs machined electrodes of varying shapes, sizes and materials to remove material from the workpiece.
Electrodes are usually made from graphite, but copper, tungsten or brass as well as combinations of these materials are also used, and the geometric features of the electrode can be customized to reach the required specifications.
In the sinker EDM process, both the workpiece and the electrode are submerged in a dielectric fluid of oil or synthetic oil and the machine guides the electrode toward the workpiece automatically using CNC technology.
As in wire EDM, as the electrode approaches the workpiece, the strength of the electrical charges breaks the barrier of dielectric fluid and a spark is created, eroding away a small amount of material by melting and vaporizing microscopic particles. The process repeats hundreds of thousands of times per second, and as material is removed, the machine continues to direct the movement of the electrode until the desired dimensions are achieved.
After the initial “roughing” pass, during which the bulk of the material is removed, we may perform additional 3-D orbiting passes in order to achieve the best surface finish and tightest tolerances possible.
Sinker EDM allows us to machine complex 3-D shapes, blind cavities, intricate internal features, threads into hardened parts, and much more. In addition, sinker EDM has the ability to use multi-up electrodes for multi-up parts production—in some cases, we can sinker EDM 100 pieces simultaneously.
CNC EDM fast hole drilling is an ideal and cost effective solution when producing holes from 0.3 to 6.0mm diameter,mainly in hard and work hardening type materials.
For example: A 3mm diameter hole to a depth of 50mm in Inconel(nickel alloy) can be achieved in under 3 minutes. Any conductive material can be processed by EDM fast hole drilling.
Applications/solutions include:anything from a wire locking hole in a socket head cap screw to a turbine engine part with hundreds of holes.
EDM Machining Process
A machining method typically used for hard metals. Electro Discharge Machining ( commonly known as EDM ) makes it possible to work with metals for which conventional machining techniques are ineffective, such as; titanium, hastelloy, kovar, inconel and carbide. EDM will only work with conductive materials. It is possible to cut small odd-shaped angles, detailed contours and produce angular holes & apertures.
Remember:The more complicated the shape,the more economical the EDM process becomes.
The EDM process is used in the tool & die industry, mould making, and is an integral part for making prototypes, and production parts for the Aerospace , Nuclear and Electronic industries.