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Electrical Discharge Machining

Electrical Discharge Machining
Intricate Geometries, Exceptional Surface Finishes, and Tolerances as Tight as ±0.002 mm
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CapabilitiesOur EDM Capabilities

Whether you require prototypes, small batches, or high-volume production, Rollmec’s EDM capabilities are fully equipped to handle your needs.

With EDM, we harness the power of electrical discharges, or sparks, to expertly remove material from the workpiece. This enables us to shape and machine even the most intricate and hard-to-cut materials with ease. The EDM process revolves around creating a controlled spark between the workpiece and an electrode (tool), which are separated by a dielectric fluid, typically deionized water. Remarkably, this machining technique does not require direct contact between the electrode and the workpiece, ensuring minimal wear and exceptional dimensional accuracy.

Types of Electrical Discharge Machining

  • In wire EDM, a thin, electrically conductive wire is used as the electrode.
  • The wire is continuously fed from a spool and guided along a pre-programmed path, cutting the workpiece as it moves.
  • This process is commonly used for cutting complex shapes and profiles in various materials, including conductive metals and alloys.
  • In sinker EDM, a specially shaped electrode is used, and it is brought into close proximity to the workpiece.
  • The electrode and the workpiece are immersed in a dielectric fluid.
  • Electrical discharges occur between the electrode and the workpiece, eroding the material in the desired shape.

EDM Specifications 

Specification Wire EDM Sinker EDM
Maximum Length 600 mm (23.62 inches) 600 mm (23.62 inches)
Maximum Width 400 mm (15.75 inches) 400 mm (15.75 inches)
Maximum Height 300 mm (11.81 inches) 300 mm (11.81 inches)
Maximum Weight 50 kg (110 lbs) 50 kg (110 lbs)
Tolerance ±0.005 mm (±0.0002 inches) ±0.005 mm (±0.0002 inches)
Materials Steel, Stainless Steel, Aluminum, Titanium, Copper, Brass, Exotic Alloys, and more Steel, Stainless Steel, Aluminum, Titanium, Copper, Brass, Exotic Alloys, and more
Minimum Wire Diameter 0.1 mm (0.004 inches) -
Maximum Taper Angle ±30 degrees -
Maximum Electrode Size - 100 mm x 100 mm x 300 mm (3.94 inches x 3.94 inches x 11.81 inches)
Maximum Depth - 300 mm (11.81 inches)

Overview Electrical Discharge Machining (EDM)

In the world of modern manufacturing, precision is paramount. Industries rely on cutting-edge technology to create intricate and complex components, and one such revolutionary process is Electrical Discharge Machining (EDM)

EDM is a unique and versatile machining technique that allows for the creation of highly precise and intricate shapes in various materials. EDM, also known as spark machining, wire erosion, die sinking, or spark eroding, is a non-traditional machining process used to shape and machine conductive materials with exceptional precision. The process involves the removal of material through electrical discharges or sparks that occur between an electrode and the workpiece, resulting in controlled material erosion.

How we workThe EDM Process: How Does It Work?

01
01 step

Setup and Preparation

Before the EDM process begins, meticulous planning and preparation take place. The workpiece is carefully selected, and the electrode material, such as copper or graphite, is chosen based on the material to be machined.
02
Step

Creation of an Electric Discharge

In the EDM process, an electric potential difference is applied between the electrode and the workpiece. As the electrode approaches the workpiece, the electric field becomes strong enough to cause dielectric breakdown. This leads to the creation of a small spark or discharge between the electrode and the workpiece.
03
Step

Material Removal

The spark generated during the electric discharge rapidly heats and vaporizes the material in its path. This causes controlled material removal from the workpiece, as tiny particles are eroded from the surface.
04
Step

Dielectric Fluid

A dielectric fluid, such as deionized water, is used to cool the sparking area and flush away the eroded particles. The dielectric fluid also acts as an insulator and helps control the spark gap.
05
Step

Shaping the Workpiece

By carefully controlling the movement of the electrode and the spark, complex shapes and features are carved into the workpiece with unparalleled precision.

FeaturesVersatile Applications of CNC Milling in Diverse Industries

Automotive Industry
Aerospace
Medical Industry

CNC milling plays a vital role in a wide range of industrial applications. One such area is the automotive industry, where CNC milling machines are used to manufacture engine components, chassis parts, and even customized prototypes.

The precision and efficiency of CNC milling enable the production of intricate parts with tight tolerances, ensuring optimal performance in vehicles.

CNC milling finds extensive application in various industries, including automotive, aerospace, medical, electronics, and prototyping. Its ability to deliver precision, efficiency, and versatility makes CNC milling an indispensable technology for manufacturing complex parts and components across diverse sectors.

 CNC milling also finds extensive use in the aerospace sector, where complex aircraft parts with high accuracy requirements are produced.

From turbine blades to structural components, CNC milling machines deliver the precision and reliability needed for critical aerospace applications.

Another industry that heavily relies on CNC milling is the medical field. CNC milling machines are instrumental in manufacturing medical devices such as implants, prosthetics, and surgical instruments.

The ability to work with various materials, including biocompatible metals and plastics, allows for the creation of customized medical solutions. CNC milling ensures precise dimensions and smooth finishes, guaranteeing compatibility and comfort for patients.

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EDM FAQs

EDM is specifically designed for conductive materials. For non-conductive materials, other machining processes like laser cutting or waterjet cutting are more appropriate.

EDM is well-suited for prototyping and small-scale production. However, for mass production, other traditional machining methods might be more efficient.

EDM produces a smooth and burr-free surface finish, often with a roughness in the range of 0.2 to 2.0 micrometers.

EDM can be cost-effective for producing complex and intricate components that are difficult to machine using traditional methods. The cost-effectiveness depends on the specific project requirements.

EDM and CNC machining are complementary processes. While CNC machining is ideal for bulk material removal and rough shaping, EDM excels in creating intricate details and achieving high precision.