Makino EDM Matters Blog - Surface Finish

Carbide Machining Without the Worry of Binder Depletion

Your DisplayName here! — Wed, 23 Jun 2010 17:14:41 GMT

EDM is a popular means of machining tungsten carbide materials, because the hardness of the material is not a concern for the EDM process. Both Wire and Sinker EDMs can used to machine fine details and near mirror finishes in tungsten carbide materials. The major drawback to the use of WEDM to machine tungsten carbide has always been the electrolytic action between the carbide material and the dielectric (de-ionized) water used in WEDM machines. This electrolytic action can actually break down the binder in the carbide, usually cobalt, and produce what looks like rust on the surface of the material. Under magnification, this break down is apparent as voids in the surface of the material (see photo 1a & 1b). These voids weaken the structure of the material, and will result in shortened tool life, especially for impact tooling such as punches, and dies used in stamping, forging, or cold heading.

WEDM using oil as the dielectric has been a slow process, historically, and there have been few of these kinds of machines produced. Makino now offers a machine designed to operate with oil dielectric, and to cut carbide and PCD materials with extreme accuracy and surface finishes. The UPV3 and UPV5 WEDM machines are the next evolution of the award winning U-Series WEDMs from Makino. Although designed for machining carbides and PCD materials, the UPV machines also perform well in tool steels. Leaving only sporadic measurable recast, and no measurable HAZ, these machines can achieve measurable surface finish results of 0.08ymRz or better! (see photo 2). For more information about these ultra-precise, oil dielectric WEDMs, watch the new Makino webinar on "Faster Cutting of Carbide and Hardened Materials."

Photo 1a – Carbide machined in oil; no cobalt depletion.

Photo 1b – Carbide machined in de-ionized water shows signs of cobalt depletion.

Photo 2 – Reflections of parts in surface of carbide block taken directly from UPV.

Edge2 Fine Hole EDM - Making the Impossible a Reality

Your DisplayName here! — Mon, 16 Nov 2009 20:09:02 GMT

I have written here in the past about EDM fine hole drilling, but I have some update info that is very interesting. Makino recently did some testing for a customer who needed a 0.007-0.008" (0.177mm - 0.203mm) diameter hole drilled through 0.75" (19.05mm) of CPM material. That's a Length-to-Diameter ratio (L:D) of 125:1. Some will say "That's impossible, it can't be done.". However, Makino Application Engineers were able to produce this very thing on the Edge2 Fine Hole machine. Using a 0.006" (0.15mm) diameter copper pipe and a tooling set-up that allows 90 degree incremental part indexing, they were able to produce a 0.0075" (0.1905mm) diameter hole through 0.75" (19.05mm) of CPM-M4. Here's a picture of the block of material with a piece of 0.004" (0.101mm) wire running through it, and magnified view of the hole itself. The hole, drilled from both sides to meet in the middle, took 30 minutes. When the part was cut open with WEDM to inspect the middle of the part where the 2 holes met, there was no visible line or mismatch at the meeting point.

EDM for aerospace

Your DisplayName here! — Mon, 23 Feb 2009 14:28:41 GMT

I have provided a lot of information on the use of EDM in aerospace manufacturing through this blog, trade events, webinars on Makino.com, and a recently published article in Makino's aerospace focused magazine, Radical Departures. These have produced a fair amount of interest from several aerospace primes and top tier suppliers, as well as MROs in the aerospace sector. I've completed the testing program to gather data for general, non-specific applications, and have sent out over 2 dozen copies of the complete test results to the companies that have asked for them.

If you have an interest in looking at EDM as a viable process in parts manufacturing for the aerospace industry, from engine parts to landing gear components, contact me to discuss how Makino can help. We are ready and willing to provide test cuts on specific materials and geometries that your company can perform metallurgical tests on to verify recast and HAZ thickness, existence of micro cracks, surface hardness, tensile strength, etc. If you would like a copy of Radical Departures, let me know and I will make sure you receive on. The test cuts and magazine are free.

Customer Support Is Very Rewarding

Your DisplayName here! — Tue, 10 Feb 2009 21:39:48 GMT

There's always a good feeling you get after reading an e-mail like this...

"It is a pleasure to write this e-mail. I wanted to express my gratitude for the support I've always received from all of my contacts with the people from SST Group. Mr. Dan Dotson keeps in frequent contact with me on any consumable items that I may need. He always finds time to call me at least weekly to provide updates on SST product updates or to offer encouragement as we navigate this difficult business cycle environment. Many thanks.

I would also like to tell you about the valuable support I receive from another of your highly qualified people. Kevin Most has probably been the biggest reason I have been successful with the investments I've made with Makino EDM's. Many, many numerous times I have clicked on his speed-dial on my cell phone over the last 2 to 3 yrs and have never not been able get in immediate contact with Kevin. I'm not talking about problems with my machines but rather application issues such as helping me by discussing the best way to burn select materials so I can quote a job, or complete a job or just enlighten me as to the capabilities of the SP43. I have one small customer that asks me to burn a shape in carbide that is actually a spline curve which often trips me up on the programming side and Kevin always finds a solution for me. Did you know that he helped me through one of these projects by exchanging e-mails while he was in Singapore last year? Yep, he found time between meetings, tours and training to get the info to me. Unbelievable. Ask him sometime how he worked me through a 4axis application for an exhaust nozzle on a jet engine that turned into a blanket order that lasted over a year and may repeat again this year.

Lately, I've been moving jobs from other wire edm's over to the Makinos to take advantage of using my 'HEAT' settings on quite thin but very rigid work pieces. I don't think 'Heat' is generally recommended for 1/4" or 3/8" thick work pieces however when the parts are in a rigid set-up and very poor flushing 'Heat' works very well.

I will not extend this email further with any more examples of how I've been supported. So let me conclude with this. Picture me in my shop, standing in front of the control on a SP43, cell phone up against my ear, saying "Kevin, how do I get it (the SP43) to do this" That says it all.

When I purchased my second Makino, I told Nick that I made my decision based on buying not just a good machine but also buying the Makino Team. I'm sure I'll feel the same when I'm ready for my third."

Sincerely,
Jack Lanphier Pres.
Lanko Industries, Inc.
Mentor, Ohio

Thanks for the e-mail Jack. It's a pleasure for all of us at Makino to serve our customers.

Amazing EDM Fine Hole comparison

Your DisplayName here! — Fri, 30 Jan 2009 16:21:58 GMT

Makino has recently done testing for a customer in the medical industry for EDM Fine Hole machining. Part of this testing compared Fine Hole EDM to Laser and conventional mechanical drilling techniques. The results of the tests were pretty amazing. The photo micrographs below show the results of all three processes. As the demand for smaller holes in medical devices, telecommunications and fiber optics, and aerospace applications increases, Makino continues to develop and refine our Fine Hole EDM machines to meet these demands. Requirements for many of these projects include accuracy of size and shape, consistency in dimensions and locations of entry and exit, and straightness through high L/D ratios. Check out these pictures and decide for yourself which process produces a better result in tight tolerance, high accuracy hole drilling. These photos were machined into 316 Stainless Steel, 0.250mm thick, and captured on a scanning electron microscope. Magnification levels are indicated on the photos.

This 0.015mm hole was developed using using a PICO second laser. Notice the deformation of the entrance hole and splattering of the exit hole.

The following 0.090mm hole was produced using conventional drilling. Notice the differing entrance and exit hole diameters and inaccurate roundness.

The next 0.020mm hole was produced using Makino Fine Hole EDMing. Entrance and exit holes were of the same quality with little to no deformation occurring to either one.

Makino fine hole EDMing was used to produce this 0.100mm hole as well. Once again the entrance and exit holes were virtually of the same quality. As you can see, little to no deformation resulted.

FW: Ti Booster technology

Your DisplayName here! — Tue, 20 Jan 2009 14:23:18 GMT

FW: Ti Booster technology
Makino has recently developed Titanium booster technology for Makino sinkers at the request of a major aerospace manufacturer. In order to use it, the EDM machine must have a generator booster that provides an additional 60 amps to the existing standard generator. What's new is the technology, or machining conditions, that provide the burn parameters for the machining - On time, Off time, Servo, Amperage, etc. The new technology is currently for high speed roughing only, and provides material removal rates of about 2 grams per minute. This is about 70-80% faster than previous technologies. Makino is currently developing finish settings for this new technology that are expected to be able to achieve finishes down to less than 2 micronRa, or 75 microinchRa. This technology will be available for most Makino sinker EDMs. We'll be broadcasting an online seminar on our Titanium booster technology this Thursday, January 22, 2009. If you'd like to attend and learn more about these advancements in titanium machining, you can register for free here. Thanks for reading everybody, hope to see you at this weeks seminar!

An Update on Our Aerospace Material Testing

Your DisplayName here! — Fri, 08 Aug 2008 15:01:16 GMT

I've mentioned in the past that Makino is doing materials testing of aerospace alloys that have been processed with EDM. Makino has shown 2 webinars addressing this topic. I will be presenting more information on this topic as a speaker at this year's IMTS in Chicago, IL on Wednesday, September 10 at 10:00 a.m. Makino EDM has had testing done on several different aerospace alloys, having just added Inconel 718 to the list of tested materials. Other alloys previously tested for HAZ, recast, micro-cracking, and Vickers Micro-hardness include 6061-T6 aluminum, 17-4 stainless, and 6Al-4V titanium. Be sure to stop by the Business and Technology Forum to see results of the latest testing performed by a NADCAP certified lab.

Wire EDM testing in progress...results soon to come.

Your DisplayName here! — Fri, 25 Apr 2008 21:57:37 GMT

I've mentioned this before here, but I want to remind everyone that Makino is doing some interesting materials testing related to EDM and aerospace manufacturing. We've already had a lot of Wire EDM testing done - 18 samples, 3 different alloys (17-4PH, AL6-4V, 6061-T6), 1, 2, and 3 pass machining. Tests performed were recast thickness, Heat Affected Zone thickness, micro cracks, and Vickers Micro Hardness. We've seen some very impressive results that you can see in our webinar archives at Makino.com . We are now in the process of testing the same 3 alloys, same tests, but with Sinker EDM burns. We'll be adding Inconel 713 in the very near future. I'll have results from these tests in the next couple of weeks, and I'll presenting this data at the Montreal Machine Technology Show on Tuesday, May 13. Anyone interested in these types of tests should stop by if you're attending the show. I'll also be supporting our Canadian distributor, SST-Canada, in their booth, number 332. If you're at the show, stop by either the technical presentation on Tuesday morning, or the SST booth to say hi. If you'd like a copy of the test results of what we've done so far, just send me an email and I'll send you a copy.

Witness lines virtually eliminated with SurfaceWIZARD

Your DisplayName here! — Thu, 17 Apr 2008 13:57:19 GMT

Hey guys, I thought I'd let you all take a look at a new test cut piece that the EDM Applications Department in Auburn Hills came up with. This part shows how well SurfaceWizard technology handles interrupted and variable thickness cuts without leaving lines at transition points. With older technology, cutting across these kinds of details would leave anything from fine witness lines, to gouges that could be several thousandths of an inch deep. The only visible line here is on the left side of the "K" in Makino. Not only did SurfaceWizard allow cutting of this part without leaving severe witness lines, the technology also helps produce a straight, flat cut along the surface being worked. This part came directly off of the machine, with no hand work or secondary operations to "polish up" the EDMed surface. For more details on SurfaceWizard technology, contact me via phone or email, or call EDM Applications at our Die Mold Technology Center in Auburn Hills, MI at 248-232-6200.

Coming up this week - SurfaceWIZARD webinar

Your DisplayName here! — Mon, 28 Jan 2008 20:19:13 GMT

If surface finish is the name of the game in your EDM world, SurfaceWIZARD is definately something you should look into. We have a webinar coming up this Thursday discussing the topic.

Register to attend at www.makino.com/events today!

SurfaceWIZARD

Mon, 17 Sep 2007 21:51:14 GMT

We had a request for some images illustrating SurfaceWIZARD, so here you go.

This diagram illustrates the flatness that can be achieved with SurfaceWIZARD in two machining passes.

This sample part shows how SurfaceWIZARD virtually eliminates lines at transition points.

Makino Introduces SurfaceWIZARD™ Wire EDM Technology

Sun, 16 Sep 2007 21:47:07 GMT

Makino is proud to announce its latest Wire EDM technology development, SurfaceWIZARD, which virtually eliminates witness lines.

SurfaceWIZARD is the newest control technology development from Makino’s EDM R&D. This technology provides exceptional surface quality in applications where the part has variable shape thickness or sudden changes in thickness, such as a stepped part. It will be an invaluable tool for shops manufacturing parts for the aerospace, medical and injection mold markets

Witness Lines

Historically, when stepped parts have been Wire EDMed the process would leave a “witness” line at the transition from one step thickness to the next. Many times the part would have a taper with variations in straightness across the machined surface. SurfaceWIZARD virtually eliminates these lines and has been shown to maintain part straightness within 5 microns in one pass and within 2.5 microns in two pass machining.

SurfaceWIZARD technology has been developed for tool steels up to 4 inches (100mm) thick, and will support 0.008” (0.020mm) and 0.010” (0.025mm) diameter wires with one and two pass conditions. This technology was developed specifically for use in poor flushing conditions where the nozzles cannot be sealed on the work surface. The technology is available as a standard technology on all Makino SP and U series Wire EDMs with the MGW-S5 control.

Demonstrated at Die/Mold Expo

The new SurfaceWIZARD control will be demonstrated at the Makino Die/Mold Expo and EDM Forum to be held September 25 through September 28, 2007 at the Makino Die/Mold Technical Center in Auburn Hills, Michigan.

For more information on this and other Makino EDM innovations, contact Makino EDM Applications or Jeff Kiszonas, EDM Product Line Manager for Makino, at 248-232-620