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Electric spark machining (EDM) is a process for machining extremely hard and exotic materials such as graphite, superalloys, and stainless steel. It is also used to produce high-precision parts with tight tolerances, complex geometries, very low surface roughness, and minimal burr.
EDM involves the use of an electrical current to erode a workpiece. A spark is created between the tool and the workpiece, and the spark melts the workpiece material, leading to precision machining. The process is also known as spark machining, spark eroding, spark tapping, and electrode tapping.
The EDM process begins by creating a gap between a tool (also known as an electrode) and a workpiece. The electrical current flow through this gap generates a spark. This spark melts the material from the workpiece. This can take place with the workpiece in its final shape or after it has been cut by the tool. The melted material is then flushed away by a dielectric fluid, and the tool makes a new pass. Control of the machining process rests on the tool motion control and the spark current, power delivery system.
Applications of EDM include machining of very hard metals, making intricate tools and components, producing small and micro parts, and drilling and milling three-dimensional complicated shapes. EDM is used in a broad range of industries including medical, aerospace, automotive, and defense.
Advantages of EDM include the ability to machine extremely hard and exotic materials, accuracies up to one micron, and the lack of burr formation (as no physical contact is made). Disadvantages of EDM include that it is a slow process and setup times can be long.
EDM is a reliable and accurate process, and can be used to produce complex shapes and features, not possible with traditional machining processes. It is also a great choice for producing extra-long, deep, and narrow holes in materials that are difficult to machine with conventional processes.
