EDM machines safety and automation

EDM and safety?

How safe is EDM? This is actually a question that worries many technicians coming in touch with EDM for the first time. The need for high voltage and reoccurring sparks make it seem like a safety hazard to inexperienced workers. As long as the machine is used according to manufacturer specification, however, there is no great danger involved.

The Metalforming Magazine gives tips on how to ensure process safety. These are some of the measures that need to be taken to run an EDM machine safely:

·         Operators and workers have to be properly trained to work with electrical discharge machining

·         Make sure that fire protection measures are installed and regularly maintained.

·         Keep an eye on the fluid: The level of the dielectric fluid is of utmost importance. The liquid prevents the discharge from crossing to conductive materials other than the workpiece.

·         Proper ventilation can clean the air of gases that might be produced in the fluid due to chemical reactions accompanying the discharge.

·         You have to monitor the dielectric fluid when it is circulating to ensure it retains its non-conductive characteristics.

EDM machines and automation

There are numerous suppliers of EDM machines. Among the most well-known producers are Mitsubishi Electric, OPS Ingersoll, Makino, Excetek, Sodick, GF Machining Solutions and Ona.

The Eagle G5 Precision is the latest addition to OPS Ingersoll's EDM machine range. The die sinking machine is said to offer high precision machining combined with low electrode wear. (Source: OPS Ingersoll)

A current trend is the automation of the EDM process. This does not only include the spark or wire erosion itself but also the machining of the electrodes. Using CNC machine tools to machine electrodes, EDM machines, cleaning and measuring stations and — last but not least — storage areas and robotic units to handle the electrodes, the EDM process can be executed automatically. This ensures that a sparker is always fed quick enough with electrodes. The machining of these electrodes and the erosion process can be programmed to take place over night, thus, making production processes much more time efficient. Additionally, a higher worklode can be processed without additional workforce. Several processes can happen simultaneously, including eroding, measuring, milling, laser engraving and cleaning. Companies that have implemented automation in their production processes have witnessed significant time savings and an increase in turnover.

Companies like Zimmer & Kreim offer automation systems particularly for EDM processes. OPS Ingersoll is another manufacturer that offers a one-stop automation solution designed to fulfill the needs of their clients in the toolmaking industry.