High Speed Cutting Technology to Replace EDM Technology
In the manufacturing industry, high speed cutting (HSC) technology has been increasingly replacing the electrical discharge machining (EDM) technique. EDM processes are commonly used to machine components with intricate shapes that are difficult to create using conventional machining methods. EDM processes require spark erosion on the workpiece surface, which need special materials, like copper and graphite, to be used as electrodes. Despite their suitability of manufacturing intricate parts, EDM processes require large amounts of time and electricity, and may generate sparks, smoke, condensation and temperature changes. In comparison, the main benefits of using HSC technology are the material types that are applicable and the much reduced cycle times for component production.
HSC technology first appeared in the late nineteenth century, with the advent of metalcutting machines powered by gas. Today, HSC technologies utilize a metal cutting tool with a rotating spindle and CNC control, to produce intricate and delicate geometries in various materials. Unlike EDM, HSC technology does not require a separate electrode material; instead, the machining process is performed with a single cutting tool. The cutting tool is capable of cutting through most materials, and can be used to produce extremely detailed parts with intricate shapes. Furthermore, since HSC technology requires no additional material such as is needed in EDM processes, it leads to a considerably lower cost and faster part production.
In EDM processes, material removal is achieved by submerging the electrode material into the workpiece surface. On being charged, high-energy discharges occur at the electrode-workpiece interface, causing local erosion of the electrode and workpiece material, and leading to the production of chip materials. The EDM process is, therefore, better suited to hard and brittle materials such as stainless steel and graphite. In comparison, HSC technology involves feedrate speeds that are measured in mm/min, and affect the cutting force and the shape accuracy of the workpiece. It is also capable of machining softer materials, including aluminum and zinc alloys.
Moreover, the high-speed colliding cutting action of HSC allows for faster production cycles than EDM, with cutting speeds being up to one or two orders of magnitude greater. This drastic decrease in cycle time is beneficial for production processes, such as prototyping, whereby repeated prototype testing is necessary. This is due to the reduced manufacturing time that HSC allows, which provides more opportunities for research and innovation, and less opportunities for costly mistakes to occur on the production floor.
Furthermore, since HSC does not require any additional material to be used, it produces less wear on the cutting tool. This allows for greater tool life since the cutting force between the tool and the workpiece is much less than in EDM processes, which can overwork the cutting tool. This can result in a much lower cost for replacing cutting tool, as well as less wastage due to the need to replace the electrode material every few usages.
In conclusion, because of its faster cycle times, increased material type compatibility, and decreased costs, HSC technology is increasingly replacing EDM as the preferred manufacturing process for intricate parts. In addition, HSC technology allows for more precise and accurate machining, as well as allowing for more dynamic and intricate geometries. This makes it a more cost-effective and practical option than EDM processes, and allows for greater opportunities for innovation and experimental manufacturing.
