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Electrical Discharge Machining

FUTUR 13/2010

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EDM from Basic Research to Industrial Applications

In tool and die making, automotive supplier technology and turbine construction, micro- and macroprducts are often processed by diesinking EDM. Electrical Discharge Machining (EDM) is the term this production technique is known by and it is particularly suitable for processing materials which are hard to machine like hardened steel and heat resistant alloys. Whats more, this technique can also be applied to electroconductive materials no matter what their mechanical material properties like hardness or modulus of elasticity might be. One decisive advantage of EDM processing is the opportunity it offers to produce contours of high geometrical complexity, form accuracy and surface quality. Since it hardly involves any process forces, EDM is especially suitable for the fabrication of microcomponents. Scientists at Fraunhofer IPK and the Institute for Machine Tools and Factory Management (IWF) at the Technical University of Berlin are now working on the modification of EDM machine tools, optimization of EDM processes and the development of new materials for electrodes. 50 percent with a reduction of processing time of around 12 percent. Scientists are currently researching applications of these electrodes in the fabrication of microboreholes for fuel injectors. ing of complex free-form surfaces of the type needed in the fabrication of turbine components made of high temperature resistant materials. One decisive advantage of EDM is the opportunity it offers to produce contours of high geometrical complexity, form accuracy and surface quality.
GP7000 engine for the superjumbo Airbus A380 (Copyright: MTU Aero Engines GmbH)

Seal Slots in High Temperature Resistant Jet-Engine Components Finest Surface Finishing of Molding Tools
In partnership with Zimmer&Kreim, a company specialized in die-sinking EDM machines, handling systems and software solutions, Fraunhofer IPK and IWF are Optimization of EDM machining of turbine components is what a joint R&D project run by Fraunhofer IPK and MTU AeroEngines is aiming for. The engine manufacturers portfolio of product parts includes stator blades, rotor blades and turbine center frames (TCF). TCF modules serve as flow channels between high pressure and low pressure turbines, channeling gases from the high pressure turbine and piping it towards the low pressure turbine. Development and manufacture of such intermediate housings are extremely complex, given the high mechanical and thermal loads they have to bear and the imperative for lightweight construction. Scientists are now involved in researching new types of electrode materials and in testing machine tool modifications for EDM processing of TCF components made of the nickel-based alloys MAR M247 and Inconel 718. They are also working on opTechnological investigations are carried out on the genius 1000 THE CUBE machine tool, which has a six axes simultaneous control and maximum stability, rigidity and precision, making it ideal for the processtimizing the die-sinking EDM of seal slots in the fabrication of parts for the superjumbo Airbus A380s GP7000 engine with the main aim of reducing processing times and relative wear of the electrodes.
Your contact M. Sc. David Carlos Domingos Phone: +49 30 6392-5105 E-Mail: domingos@iwf.tu-berlin.de

EDM serves a wide range of applications. Researchers at Fraunhofer IPK have also recognized the technologys potential in combination with laser drilling for the fabrication of high precision drills. The MicroDrill project strives at developing a hybrid machine system that combines the physical and technical benefits of laser drilling and micro-EDM. Together they guarantee high speed and precision for the cost-effective, high performance production of bore holes. Read more on p. 14

Tight manufacturing tolerances of two micrometers, low surface roughness down to 0.05 micrometers and low process forces make EDM especially interesting for the micromachining of microdies and molds, cooling holes for air injection nozzles and turbine blades. Yet the technology is also
6-axis-die-sinking EDM machine tool for manufacturing free-form surfaces and large-scale microstructured components and systems (Copyright: Zimmer&Kreim)

Electrodes made of Diamond

Current R&D work in micromachining is focused on investigation and application of diamond-based electrode materials for micro-die-sinking EDM. Conventional electrode materials like tungsten-copper and cemented carbide wear out quickly. As over 30 percent of relative wear occurs during microprocessing, electrodes need frequent replacement otherwise the form accuracy of the microcomponents suffers. Diamond, on the other hand, has a high melting point and much higher thermal conductivity than conventional electrode materials which makes it predestined for usage as electrode material. Successful tests have already been conducted using boron-doped CVD diamond and PCD diamond doped with cobalt for micro-EDM which showed that the relative wear on the electrodes could be reduced by over

working on the optimization of die-sinking EDM processes in the fabrication of molding tools. Such molding tools are used both on the micro- and macrolevel for replication of microstructured plastic parts and for fabrication of a wide range of plastic micro- and macrocomponents. The working alliance aims to improve achievable surface quality in the die-sinking processing of mold steels and cemented carbides. The electrodes used in the research are made of electrolyte-copper and tungsten-copper. Electrode geometry is varied in sets of tests with the aim of achieving replicable surface quality.

used for fabrication of injection molds of hardened steel for replication of micropolymer parts such as connectors and microfluidic (lab-on-a-chip) systems. The disadvantages of this manufacturing process lie in its low material removal rates, its thermal influence on the workpiece surface layer and difficulties in waste disposal. These are all areas which research and development engineers at Fraunhofer IPK and IWF are investigating with the main aim of increasing achievable material removal rates and drastically reducing electrode wear, especially on the micro level.