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Small Hole EDM Services


Small Hole EDM Primary

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High-speed small hole edm is a specialized field of electrical discharge machining. A small .010" - .118" dia. (.25mm - 3.0mm) usually hollow electrode spins about a spindle much like a drill and drill bit (edm drill). The electrode is electrically charged by a servo-controlled generator producing the spark. Water based dielectric flushes through and around the electrode providing a controlled environment for the extremely small sparks to jump to the work piece. The sparks erode the surface of the work piece creating very small pockets. Eventually millions and millions of these microscopic pockets create the small hole. The size of the hole is controlled by the diameter of the electrode and the power settings. The location and depth of the holes are driven by CNC ISO codes eliminating operator error. The machines available at Xact have automatic electrode changers for efficient unattended machining.

Small hole edm is in many ways similar to a drilling operation but it offers the advantages of edm. Very low machining forces make the drilling of delicate parts possible. The work piece hardness or angle of entry have no detrimental impact on performance. Holes are virtually burr free.

Up to 14" part height possible, depending on part configuration.

Max. XY travel: X-22" & Y-14", other sizes may be available with lead time and/or large quantity orders.



Capabilities · Specifications · Equipment Used · Inspection Equipment · Additional Information

Capabilities

Small Hole EDM Common Applications

Coolant holes in hardened machine tool bits for taps, end mills, and drills
Addition of wire edm start holes after heat treating
Removal of broken drill bits
Placement of holes too small/difficult for conventional drilling
Burr free holes

Other Services

Prototyping
Reverse Engineering
Inspection
Laser Marking
Wire EDM

Production Quantity

1 Part to 100,000+ Parts

Quality Control Certifications

ISO 9001:2008

Quality Control Process

CMM
SPC
Video

Software Used

CADKEY
Esprit
PEPS Camtek
SolidWorks

Specifications

Materials

All Tool Steels
Stainless Steel
Aluminum
Inconel
Tungsten
Carbide
Nickel
Brass
Copper and Copper Tungsten
Kovar
Invar
Platinum
Molybdenum
Titanium
Nitinol
Tantalum
Hastalloy
Poly Crystalline Diamond (PCD)
Refractory Materials
CPM – 10V

Electrode Diameter

0.010 to 0.118 in

Finished Hole Diameter

0.012 to 0.126 in

Part Height

Up to 14 in

Maximum XY Travel

X-22.0 in
Y-14.0 in

Tolerances

+/- 0.005 in

Acceptable File Formats

DXF
DWG
IGS
PRT
X - T
STP
SLDPRT
Native Solidworks
PEPS

Equipment Used

1 - Japax Custom Built CNC EDM Drilling Machine

10.6" x 19.9" travel

1 - Charmilles SH-2 Small Hole EDM Machine

7.8" x 11.8" travel

2 - Current CT300 CNC EDM Drilling Machine

12" x 8" travel
Automatic electrode changer

1 - Current CT500 CNC EDM Drilling Machine

14" x 22" travel
Automatic electrode changer

1 - Sodick K1CN CNC EDM Drilling Machine

11.8" x 15.7" travel

Inspection Equipment

OGP Avant ZIP 300 Video Inspection System (multi-sensor)

12" x 12" x 8” travel
38 X to over 300 X magnification
Automated Reverse Engineering
Equipped with 1/10th Micron Glass Scales (4 Millionths Resolution)

OGP Smartscope ZIP 250 Video Inspection System

6" x 10" travel

OGP Flash 500 Video Inspection System (multi -sensor)

18" x 18" travel

OGP Avant 600 Video Inspection System

18" x 24" travel

1 - Brown & Sharpe Global Image 575 CMM

Available with PH10M indexable head and PCDMIS CAD++

2 - Brown & Sharpe Reflex 454 Coordinate Measuring Machines

18" x 20" x 16" with reverse engineering capabilities

2 - 14" Profile Projectors

Available with 10x 20x and 50x lenses and linear digital scales

2 - Sets of Mitutoyo Digimatic Holtest gages

Available with .0001" accuracy

1 - Mitutoyo Height Master

Available with .00005" graduations and digital readout

Other Equipment

Optodyne MCV-500 Laser Doppler Displacement Meter
1 - Mahr Digimar CX 1 Height Measuring Station
Minitab statistical software package
Advanced CAD/CAM equipment with file transfer and translation capabilities
GT Schmidt Microlase laser marking and pin stamping systems

Additional Information

Small Hole EDM Advantages

Burr free
Large depth to diameter ratios
Very low machining forces facilitate the drilling of delicate parts
Machining performance is not affected by the work piece hardness or angle of entry

Specialties Served

Machined Parts
Stamping Dies
Trim Dies
Extrusion Dies
Mold Components and Electrodes
Gauges and Fixtures
Prototypes
Endmills
Reamers
Taps
Cutting Tools
Exotic Materials
Form Tools
Blanking Punches
Medical Components

Industries Served

Automotive
Consumer Products
Paper Processing
Defense
Electronics
Energy
Food Processing
Marine
Medical
Packaging
Aerospace
Nanotechnology
Cutting Tools

 MORE IMAGES 

· CT500-CT-300 EDM

· Drilling with Small Hole EDM

· ED Bore

· Filler Nozzle #1

· Filler Nozzle #2

· Hole Drilling in Tube

· Mold Block

· EDM Inspection Equipment

· Avant ZIP 300 Video Inspection System

· CAD/CAM software

· Coordinate Measuring Machine

· Medical Components

· Multi-operation Production Parts

· Typical Wire EDM Parts

· Marine Industry Mold

· Communication Industry Thin Walled Production Part

· Aluminum Component

· Small Parts Example #1

· Small Parts Example #2

· Small Parts Example #3

· Laser Marking #1

· Laser Marking #2

· Endoscopy Rings

· Fibre-Optic Clips

· Mold Core Electrical Connector

· Small Gears

· Titanium Part for Heart Instrument

· Shop Facility #1

· Shop Facility #2

· Programming

· Building

 DOWNLOADS 

width= Small Hole EDM Capabilites Chart
(PDF, 11KB)

width= Waukesha Plant Quality Certification
(PDF, 588KB)

width= Cary Plant Quality Certification
(PDF, 588KB)

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