Meaning
Thermal removal process uses controlled electrical discharges to shape hard conductive materials. Since physical contact between the tool and the workpiece is absent, electrical discharge machining avoids the mechanical stresses associated with traditional cutting. The process relies on a dielectric fluid to act as both an insulator and a cooling agent.
Thermal Removal
Intense heat generated by a series of sparks melts and vaporizes small amounts of metal. During electrical discharge machining, the tool and the part are separated by a tiny gap. Sparks jump across this gap when the voltage exceeds the dielectric strength of the fluid.
The resulting erosion creates a cavity that perfectly mirrors the shape of the electrode.
Precision Application
Intricate geometries that are impossible to mill or turn become achievable through this method. Small holes, sharp internal corners and thin walls are common features produced with electrical discharge machining. The absence of tool pressure allows for the machining of fragile parts that would otherwise deform.
This makes it a preferred choice for the production of molds and dies in high strength alloys. The process operates independently of the hardness of the material, provided it can conduct electricity.
Electrode Erosion
Wear on the tool itself remains a constant consideration in the workflow. While electrical discharge machining removes material from the part, the electrode also loses mass over time. Specialized software and compensation techniques account for this loss to maintain dimensional accuracy throughout the run.
