Selection and maintenance of EDM drilling machine consumables

    The EDM drilling machine is a high-precision processing equipment widely used in mold manufacturing, aerospace, automobile manufacturing and other fields. Its processing principle is mainly to generate electric spark discharge between the electrode tube and the workpiece to erode the workpiece material, thereby achieving the purpose of punching. In the use of the EDM drilling machine, the selection and maintenance of consumables are very important, which is not only related to the processing efficiency, but also directly affects the processing quality and the service life of the machine.

    Accessories and consumables of EDM drilling machines play a key role in the operation and processing of the machine:

    1. Electrode tubes

    Electrode tubes are indispensable consumable parts of EDM drilling machines and are also one of the common consumables. During the drilling process, the electrode tube has a large loss. Generally, a 400MM electrode tube, excluding the clamping part, can only punch less than ten 30mm holes. The thicker the workpiece, the greater the loss of the electrode tube. Therefore, the quality of the electrode tube directly determines the drilling effect and the life of the consumables.

    1.1 Types and diameter ranges of electrode tubes

    The electrode tubes of the EDM drilling machine are divided into two types according to the material: copper electrode tubes and brass electrode tubes. The commonly used electrode tubes diameter ranges from Φ0.3 to Φ3.0mm, and the commonly used lengths are 400mm and 500mm. When selecting electrode tubes, you should make a reasonable choice based on the material and thickness of the workpiece. For example, when processing steel (such as SKD-11), brass electrode tubes are usually used; when processing tungsten steel (such as: YG8, KG5), copper electrode tubes are required.

    1.2 Precautions for replacement and installation of copper tube electrodes

    When replacing the tube electrode tube, at first, it should be careful to avoid bending the electrode tube, then put the water-stop seal on the electrode tube, and make the electrode tube extend 2mm to 3mm from the water-stop seal. Then put the electrode tube into the drill chuck, tighten the water-stop seal on the chuck, and finally tighten the lock nut on the spindle. At this time, check whether the electrode tube is in the center of the chuck to ensure correct installation.

    2. Rubber seals

    Rubber seal is another important consumable in EDM drilling machine, mainly including electrode tube seals and water pump seals. Since EDM drilling machine works in a high-pressure cooling environment, the quality of the seals directly affects the normal operation and processing effect of the machine.

    2.1 Electrode tube seals

    The electrode tube seal is a component used in conjunction with the electrode tube, mainly used to prevent water leakage at the electrode tube. If water leakage is found at the electrode tube during use, the seal should be replaced in time to ensure the normal operation of the electrode tube and extend its service life. When selecting the electrode tube seal, ensure that its material and size are consistent with the machine  requirements to ensure the sealing effect.

    2.2 Water pump seals

    The water pump seal is used for the high-pressure water pump of the EDM drilling machine. Since the water pump is running under high pressure for a long time, the seal is easy to age and cause water leakage. It is recommended to check the high-pressure water pump regularly to maintain a normal oil level. If water leakage is found, the seal should be replaced in time to avoid damage to the pump.

    3. Wire guides

    The quality of the wire guide determines the quality of processing. It is generally composed of: metal shell, ceramic sheet (gem sheet), mainly used to guide the movement of the electrode tube, ensuring that the electrode tube can accurately move along the preset trajectory during processing. The inner hole accuracy and surface finish of the ceramic sheet (gem sheet) directly affect the accuracy of the processed hole and the position accuracy. The electrode tube is required to pass smoothly without astringency, and the gap should be controlled within 0.05mm.

    4. Rotating spindle

    The rotating spindle is an important part of the EDM drilling machine, mainly used to support and drive the movement of the electrode tube. The rotating spindle has high precision and stability, which can ensure the position and movement accuracy of the electrode tube during the processing. It usually includes spindle motor, lead screw, guide rail and other components, and realizes the up and down movement and rotation of the electrode tube through a precise transmission device.

    5. Working fluid system

    It is mainly used to provide cooling and chip removal functions. During the EDM drilling machine process, the working fluid can quickly cool the discharge area, reduce the loss of the electrode tube and the thermal deformation of the workpiece, and at the same time discharge the eroded workpiece material particles from the processing area to keep the processing environment clean. The working fluid system generally includes working fluid tanks, high-pressure water pumps, filters, pipes and other components.

    6. Power system

    The power supply system is one of the core components of the EDM drilling machine responsible for providing stable EDM discharge energy. It can convert the input electrical energy into high-frequency pulse electrical energy suitable for EDM, and adjust the processing effect by controlling the discharge parameters (such as voltage, current, pulse width, etc.). The performance and stability of the power supply system directly affect the processing accuracy, efficiency and surface quality.

    7. CNC system

    The CNC system is the brain of the EDM drilling machine, which is responsible for coordinating and controlling all parts of the equipment. The control system can automatically adjust the electrode position, feed speed, etc. through preset programs and parameters to achieve precise processing. At the same time, it can also monitor the operating status of the equipment in real time, such as current, voltage, temperature, etc., and promptly alarm or shut down when abnormal conditions occur to protect the safety of machine and operators.

    8. High pressure water pump

    The high-pressure water pump is mainly used to provide high-pressure coolant to ensure the stability and effect of the processing. It is recommended to regularly inspect and maintain the high-pressure water pump, and replace damaged seals and other parts in time to ensure the normal operation of the water pump.

    In order to ensure the efficient operation of the EDM drilling machine and extend its service life, the following are some suggestions on the selection and maintenance of consumables:

    8.1 Select high-quality consumables

    When choosing consumables such as electrode tubes and seals, you should try to choose products with reliable quality and stable performance to ensure the quality and compatibility of consumables.

    8.2 Regularly check and replace consumables

    Regularly check the consumables of the EDM drilling machine and replace damaged or aged parts in time. For example, regularly check the wear of the electrode tube and the sealing effect of the seal, and replace damaged parts in time to ensure the normal operation of the machine.

    8.3 Keep the working environment clean

    Keep the working environment clean, regularly clean up the machine and workbench to prevent impurities from entering the working fluid and the inside of the equipment, thereby reducing wear and damage to consumables.

    8.4 Strengthen operator training

    Strengthen the training of operators so that they can master the correct equipment operation and maintenance methods to avoid damage to consumables and equipment failures caused by improper operation.

    The efficient operation of the EDM drilling machine is inseparable from the support of high-quality consumables and reasonable maintenance management. By selecting appropriate consumables and regularly checking and replacing them, the service life of the equipment can be effectively extended, the processing efficiency and quality can be improved, and greater economic benefits can be created for the enterprise.