Making a splined shaft with the die sinker EDM

Tried to make a splined shaft with the Charmilles Form 20 CNC die sinker. Not optimal yet (electrode wear, electrode oversizes, surface finish on the part etc.) but okay for a first try.
#machining #edmmachining #sinkeredm #electricaldischargemachining #diesinker #zerspanung

[@brunobrauchmeier4766]

...Thanks fo videos!

[@ofthenightffs]

Really cool process! Wouldn't it have been better to have the profiles in the opposite order though, so that the finishing pass has the most rigid position, closest to the probe?

[@flo_5235]

Yes! That's exactly what I was thinking as i had cut this big hole for probing in the electrode.

[@davidclifford9774]

What is total cutting time for the part? It looks great!!

[@flo_5235]

About 70 minutes. But roughing was way to aggressiv, so with acceptabel wear on the roughing electrode it would take a little bit longer.

[@rjung_ch]

👍💪✌

[@loganosmolinski4446]

Boop

[@Sketch1994]

Does the finishing electrode orbit/helix/circle around the shaft (I am guessing it is oversized since it drops down without eroding anything)? How would you go about preventing marking the bottom face?

[@flo_5235]

None of the electrodes orbits around the shaft. The finishing electrode drops down so far without eroding is because the oversize between semi fininishing and finishing isn´t enough. The same for roughing and semi finishing but not that much. Some flushing around the electrode should prevent the marking on the bottom face and maybe save some wear on the roughing electrode. I have to play arround with that kind of setup a little bit but thats why I tried this out.

[@Sketch1994]

@@flo_5235 So you mean the semi finishing electrode only left a bit of tapper from wear towards the bottom? So the errosion starts only at the closest part of a tappered wall even if it is going to end up cutting further than it (the top of the finishing electrode didn't seem to be sparking in the beginning of the cycle)? PS: Amazing work nonetheless. Thank you for taking the time to make videos of it!

[@flo_5235]

Thanks a lot! Yes, exactly. The plan was that the finishing electrode would burn all the way down too but there wasn´t enough stock left (except the corners where the semi finishing electrode wears). As the spark gap changes with different EDM settings (roughing, semi finishing, finishing) its not that easy to find the right oversizes between the electrodes. To much oversize and the erosion takes far to long and the semi finsihing and finsihing electrode wear more than necessary, to little oversize and the semi finsihing and finishing electrode don´t have material to work with and the surface finish on the part is bad (as in my case). Just my thougts, I´m not 100% sure if this is correct.

[@youssefcherki7228]

hello can you gave me you email i want to know price of EDM thread and more information