Copper electrodes:
Wire-Cut EDMing after milling and hole EDMing
- ALC600G iGE = 12.5 h, 3 cuts, Ra 0.64, taper 0.5°
AL60G machining = 42 hours, Ra=0.47 µm
Sodick Die-Sinker EDM Machining Samples & Application
Turbine wheel of cryogenic pump for liquid hydrogen (t=-170°) supply
- extra strong granular metal
- turbine wheel dia = 190 mm
- total metal removal volume – 1900 mm3
- total machining time – all blades on 2 sides = 12 days
Simultaneous 5 axes EDMing
Turbine wheel of cryogenic pump for liquid hydrogen supply
- extra strong granular metal (115-120 kg/cm2)
- space between turbine blades = 2,3 mm
- turbine wheel dia = 190 mm
- total metal removal volume – 3300 mm3
- total machining time – 7 days (4 electrodes of 4 shapes for 4 blades on 2 sides)
Deep cavity EDMing sample
Sodick AL60G Sinker EDM.
• Depth: 40 mm
• Machining time: 10 hours
• Copper electrodes: 2 pcs
• Electrode area: 460 mm² each
• Electrode offset (undersize): 0.6 mm
• Surface finish: Ra 0.47 μm
Wall plug mold sinking:
2 electrodes, undersize 0.3 fine – 0.5 rough. LORAN – BAREL.
Crosscut surface = 4800 mm2.
Time=8 h 50 min for one machining.
In the photo there are 4such machinings.
- Smallest Corner R Machining
- Stainless St – Cu, depth 0.3 mm
- Surface Finish – Ra 0.12 µm
- Bottom Corner R – 4 µm
SGF+ machining sample
- Multi-hole Machining by Intricate Electrode
- Stainless steel – Cu electrode, depth 5 mm
- Surface Finish – Ra 0.072 µm (Rz 0.41 µm)
- Electrode Wear – finishing 0.002 mm (bottom)
Machining WC workpiece CuW electrodes using “TPC4”. Total Machining Time reduced by 28%
Steel EDMing sample
(XYZ & С 4-axes simultaneous control):
- depth: 10 mm
- roughness: Rz=2,6 µm / Ra=0,7 µm
- machining time: 17 hr 10 min
- electrode: copper
- indexing angle: 20 °
Die-sinker EDM has become an indispensable manufacturing technology wherever conventional machining reaches its limits. Unlike milling or grinding, EDM produces complex three-dimensional cavities, deep narrow ribs, sharp internal corners, intricate micro-features and mirror-like surfaces without introducing cutting forces into the workpiece.
Today, Sodick Flat Linear Motor Die-Sinker EDM machines are used across virtually every high-precision industry. They manufacture moulds for plastic injection, pressure die casting, forging and powder metallurgy, while also machining stamping dies, extrusion tools and precision punches. In aerospace, they produce turbine blades, blisks, cooling channels and components made from difficult-to-machine superalloys. Medical manufacturers rely on EDM for surgical instruments, implants and miniature precision components. Electronics, semiconductor, optical and watch industries use it for micro-features measured in only a few microns.
Another important application is machining tungsten carbide, polycrystalline materials and other extremely hard conductive materials, where traditional cutting tools suffer from rapid wear. Advanced Sodick technologies such as SGF+ NANO, TPC4, Perfect Active Control and ultra-fast Flat Linear Motors provide exceptional machining stability, minimal electrode wear and outstanding surface quality even in the most demanding applications.
The ability of Flat Linear Motors to maintain an optimum spark gap with servo corrections up to 1,000 times per secondalso enables No-Flush EDM machining in many applications. By eliminating conventional flushing, manufacturers can reduce defects caused by unstable dielectric flow, improve dimensional accuracy and machine deeper, narrower cavities that would be difficult or impossible using conventional EDM technology.
From micron-scale precision components to large aerospace tooling, Sodick Die-Sinker EDM machines combine accuracy, productivity and long-term reliability, making them one of the world’s most advanced solutions for precision electrical discharge machining.
SGF+ machining sample
(Gr electrode NANOwear):
EDM sinking of a cavity in steel with a graphite electrode. The corners of the workpiece are well machined and there is no wear on the electrode. On the left is the same cavity before machining.
Tungsten carbide machining sample:
Electrodes: copper-tungsten х 3
Dimensions: Ø 5,24 mm, depth 15 mm
Roughness: Ra 0,61 µm
Undersize: 0,12 mm/side
N0-flush Machining
(the part is cut into 2 parts with a Wire-Cut EDM to show the surface quality).
Gr-St EDM machining sample:
An example of electric discharge sinking of a deep, narrow groove cavity without flushing the dielectric fluid (sludge removal due to the pumping effect of ultra-fast electrode movements)