Current Status and Trend of CNC EDM Technology

At present, the rapid development of the mold industry has promoted the advancement of mold manufacturing technology. As an important branch of mold manufacturing technology, EDM is being given higher and higher processing requirements. At the same time, under the influence of the new situation of CNC machining technology development, the EDM technology is rapidly developing towards a deeper and higher level of numerical control. Although the rapid development of high-speed mold processing technology has made electrical processing face severe challenges, some processes of EDM have been replaced by high-speed machining centers, but EDM still has broad prospects. For example, in the complex, precise small cavity, narrow slit, groove, corner, pop hole, deep cutting and other processing fields of the mold are still widely used. At the same time, this technology has been improved and upgraded, making EDM technology lasting in the mold industry. The rapid development of advanced manufacturing technology and the intensification of competition in the manufacturing market have put forward higher requirements for CNC EDM technology, and also provided new development momentum.

1 Basic status of the development of CNC EDM technology

1.1 CNC EDM technology is constantly developing in the direction of precision, automation, intelligence and efficiency. Nowadays, new types of CNC EDM machines are emerging one after another. For example, Swiss Archie, Swiss Charmilles, Japan Sodick, Japanese Makino, and Japanese Mitsubishi have all improved their technology in this area.

Precision

The precision core of EDM is mainly reflected in the requirements of dimensional accuracy, profiling accuracy and surface quality. Nowadays, the precision of CNC EDM machine tool has been improved. The size processing requirement can reach ±2-3μm, the bottom corner R value can be less than 0.03mm, and the best machined surface roughness can be lower than Ra0.3μm. Through the use of a series of advanced processing techniques and processes, mirror processing can be achieved and EDM can be successfully completed in high-precision mold parts such as micro connectors, IC plastic packages, mobile phones, and CD cases. Overall, modern mold companies have not been able to dig out the precision machining performance of machine tools in the application of advanced CNC EDM machines. Therefore, it is necessary to comprehensively promote the further development of existing CNC machining technology and continuously improve the precision of mold processing.

Intelligent

The emergence of intelligent control technology has pushed CNC EDM to a new level of development. The new CNC EDM machine uses intelligent control technology. The expert system is an important embodiment of the intelligentization of CNC EDM machine tools. Its intelligence is reflected in both accurate detection technology and fuzzy control technology. The expert system adopts the man-machine dialogue mode. According to the processing conditions and requirements, the machining program can be automatically created after the set value is input reasonably, and the best processing condition combination is selected for processing. Online automatic monitoring and adjustment of the processing process to achieve optimal control of the machining process. When the machining system detects the machining conditions, the input machining shape, electrode and workpiece material, machining position, target roughness value, electrode scaling amount, shaking mode, taper value and other indicators can be automatically calculated and configured. The fuzzy control technology is to monitor the state of the EDM machining gap by computer monitoring, automatically select the processing conditions that maximize the machining efficiency within the range of maintaining stable arc; automatically monitor the machining process to achieve the most stable control technology of the machining process. The application of expert system intelligence technology makes machine tool operation easier and requires less skill level for operators. At present, the intelligent technology is continuously upgraded, making the application range of intelligent control technology more extensive. As the market demands for electrical processing, intelligent technology will gain a broader space for development.

automation

At present, the most advanced CNC EDM machine is equipped with an electrode library and a standard electrode fixture. As long as the electrode is loaded into the tool magazine before processing and the machining program is programmed, the entire EDM process can be automated. It runs almost without manual operation. The automatic operation of the machine tool reduces the labor intensity of the operator and improves the production efficiency. However, the price of automatic device accessories is relatively expensive, and the configuration of CNC EDM machines for most mold companies is not complete. The functions of automatic measurement and alignment, automatic positioning, and continuous machining of multiple workpieces of CNC EDM machine have already exerted its automation performance. The automatic operation process does not require manual intervention, which can improve the processing accuracy and efficiency. The degree of automation of machine tools is one of the development trends of the current CNC EDM machine industry.

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