06.

2007

Contents

1 Process technique....................................................3
1.1 Working Condition ..............................................3

1.2 Dielectric liquid ...................................................3

1.3 Planetary machining...........................................7

1.4 Polishing with Agiebril...................................... 8A

1.5 Systematics of intervention ............................. 8B

2 Workpiece ............................................................. 8D
2.1 Preparation of the Workpiece .......................... 8D

2.2 Pre-machining of the workpiece ....................... 10

3 Electrodes .............................................................. 11
3.1 Impulse Selection and Application.................... 11

3.2 Electrode Planning ........................................... 15

3.3 Manufacture of electrodes ................................ 22

SA Series
4 Precision ................................................................ 27
C5. Technology 4.1 Environmental influences ................................. 27

4.2 Influences due to the system............................ 27

4.3 Human influences............................................. 27

5 Impulse introduction ............................................... 30

5.1 Impulse Data 1 ................................................. 30

5.2 Impulse Data 2 ................................................. 33

5.3 Influence of the parameters.............................. 35

6 Process Data.......................................................... 38
7 Screw Operation .................................................... 40
8 Abbreviations and symbols .................................... 42
9 Impulse Name ........................................................ 44
10 Surface Finish Conversion Chart ............................ 46
11 Setting guidelines.................................................... 47
11.1 IMPORTANT NOTES! .................................... 47

11.2 Surface Finish Selection ................................. 47

11.3 Roughing Impulse Selection ........................... 47

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1 Process technique

1.1 Working Condition

1.1.1 Materials

● It is possible to erode all materials having an electrical conductivity higher then 1 S/cm
(0.1Ω-1cm-1).
Their hardness doe not have any effect on the process.
● The material must not undergo violent chemical reactions with the dielectric liquid (non
combustible).
● The material must be suitable for clamping (hardness, rigidity, plasticity).

1.1.2 Workpiece

The blank dimensions of the workpiece must lie within the worktank dimensions, and the
contours within the traverse zone.
The workpiece must be suitable for clamping and must not exceed the permissible weight.

1.1.3 Disturbing factors

• Not homogeneous material (segregation, blowholes), causes fall in performance and shape
errors.
• Not stress-annealed material, causes shape and position errors.
• Carbide with high titanium carbide and tantalum carbide, causes fall in performance.
• Temper errors causes shape and position errors due to internal stresses
• Temperature variations during erosion of large workpieces causes variation of the linear
dimensions.
• Thin, narrow necks (tongue formation) and thin deep slots (bad flushing) causes instability.

1.2 Dielectric liquid

1.2.1 The functions of the dielectric are

● to trigger off and assist the discharge

● to cool the electrode and the workpiece
● to evacuate the material removed

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1.2.2 Flushing

It is very important that during ED machining the dielectric should be neither too clean nor too
dirty. The special feature of good flushing is its uniformity. In order to keep the EDM area clean 3
types of flushing can be used:
• Flushing by motion (timer)
• Lateral flushing
• Central flushing

Flushing by motion
In most cases the movement of the electrode during machining (timer, planetary motion, rotation)
is sufficient to ensure adequate flushing.
Flushing through movement, which usually guarantees better dimensional accuracy than flushing
through boreholes, increases machining time slightly. However, since it simplifies both electrode
production and the preparation of the workpiece and the machine, the overall effect is reduced
expenditure of time and money.
This type of flushing is managed by the machine and not by the operator, it is intended for
automatic jobs and guarantees uniform wear.

Timer Planetary motion

Lateral flushing
Lateral flushing assists the process
but has various side effects. It
depends exclusively on the
operator's experience, it can only
be used with difficulty in automatic

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jobs and it causes irregular wear.

Is used usually under pressure and combined with the timer.

Central flushing

Flushing holes
Flushing holes can, however, prove necessary with large electrodes or electrodes with complex
shapes. Flushing holes can be made in the electrode or the workpiece.

Location of the holes

The holes should be made so that they guarantee as uniform flushing as possible and
evacuation of the gases.
Exit of gases (ev. suction)

Zone with poor Better solution

flushing Pressure

Hole diameter
An excessively large hole sometimes prevents uniform a
a
flushing.
The difference between a and b must be as small as b
b
possible. Shape to be eroded

Carrot formation
Flushing hole
The drill cores or “carrots” left behind after machining core
when using electrodes with flushing holes must be
removed. It is therefore advisable to prevent their
formation as far as possible.

Core elimination
Smaller flushing holes Planetary motion (the
Inclined flushing holes
Diameter < 2GAP electrode must be smaller)

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Flushing holes in the workpieces

If these do not disappear after machining, they must be plugged, unless they do not interfere with
the function of the workpiece, or even are useful, e.g. as injection channels in die casting, etc.

Use a flushing chamber for flushing through the workpiece during electric discharge machining.

Flushing chamber

a. For pressure flushing Electrode

Workpiece

Flushing chamber

Electrode

b. For vacuum flushing Workpiece

Flushing chamber
Contral valves for
pressure
compensation

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1.3 Planetary machining

Planetary machining is highly rational: It assists the flushing, permits better distribution of the
wear (i.e. a higher degree of geometrical accuracy) and yields savings in electrode manufacture
(fewer electrodes and standard undersizes).

Benefits

• Improved flushing
• Reduced wear → fewer electrodes
• Standard undersizes

Application

The use of planetary machining is practically always advantageous and is in some cases
especially useful, even indispensable.

• Polishing

• Sharp edges

• Machining of recesses

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Circular widening
The outer angles (opposite the
electrode) are rounded by the
widening radius R + gap.
Electrode
The inside angles on the other hand
are reduced by R + gap. Engraving

Characteristics of planetary machining

During planetary eroding the electrode moves relative to the workpiece about its main axis,
according to the selected strategy until the programmed nominal dimension is attained. When
planning the electrode it must be taken into account that the shape produced by the movement
differs from that of the electrodes.

Planetary movement

Main axis

Electrode planning for planetary movement

The undersize of the electrodes for the planetary movement can be the same, and it must be
larger than undersize 0.8 M for roughing (see “Undersizes” or “Determining undersizes” and
“Planning table”). The system will calculate and compensate the difference of the dimension
automatically

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1.4 Polishing with Agiebril

1.4.1 Workpiece Material Re-quirements

Note: only for equipment on which this function is available.

• No carbides
• Hardness of the basic structure: > 50 HRC
• Carbon content < 0.8%
• No ledeburite alloys
• Maximum purity

The following materials have been utilized successfully: 90CrSi5, 100MnCrW, X38CrMoV51,
X40CrMoV51

1.4.2 Technology

In order to obtain a high surface quality one should use a maximum of four impulses prior to the
Agiebril impulse.

1.4.3 Thermal expansion

1. Cavity too deep; no frontal polishing and with small lateral polish imperfections
Reasons: a) The warming of the roughing electrode has resulted in such a longitudinal
dilation that not only there wasn’t any material left for finishing and polishing
but the final depth has been exceeded.
b) Due to smallest positioning errors or lateral thermal expansion of the roughing
electrode, laterally too there wasn’t enough material for polishing at disposal.
Preventive measure: Set a higher compensation correction (see “Semifinishing and finishing”) of
the roughing electrode than standard, e.g., frontally 1.35 and laterally 1.1 instead of standard 1
and 0.8 respectively.

2. Good polish quality at cavity too deep

Reasons: The electrode used for Agiebril has a lower temperature during polishing than
during machining. Preventive measure: Make sure that during positioning to
Z = 0, the polishing electrode has the same temperature as the dielectric
circulating in the work tank (e.g., by immersing the electrode for ten minutes in
the dielectric prior to positioning).

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1.5 Systematics of intervention

The Tectron (cycle that automatically optimises the EDM process) of advanced equipment (for
example Agietron Exact) is able to identify particularly critical machinings and to implement all the
EDM optimisations suitable for finishing the job without any intervention on the operator's part.
Nevertheless, some adverse circumstances may generate results different from that intended, in
particular the two following situations may happen:

ED machined surface blemished

The causes of non-uniform or blemished surfaces are:

• Evacuation of the sludge not optimal
• Pulses too aggressive
• Undersizes not respected
The finer the surface is, the more acute the problem becomes. The first interventions are:
1 Set a timer EDM time very short (0.3-0.4 seconds)
2 Increase the pause and reduce the compression
3 Switch the fuzzy-control out
Intervention 1 does not have a great influence on the machining time, while interventions 2 and 3
increase it.

High erosion time

When you are confronted with EDM times which are too long, it is very important as a first step to
make an analysis in order to establish where time is being lost. In particular, you must analyze if
the loss of time is during roughing, during finishing or during the passage from one electrode to
the following one.
When this analysis has been made, it is necessary to establish if the increase in EDM time is due
to the fact of not being able to load the electrode with sufficient energy or because the geometry

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of the electrode does not permit evacuation of the sludge, thus making the ED machining very
unstable.

Roughing

If the loss of time takes place in roughing, one of the main causes is the fact that insufficient
current has been given to the first roughing pulse. As a rule, one graphite electrode of approx.
12A/cm2and one copper one of approx. 8A/cm2can be loaded. It is, however, necessary first of all
to make allowance for the undersize of the electrode in order not to ruin the surface already
during roughing. In order to give more current than that allowed by the undersize, you must know
the GAP and M values well.
It is up to the operator to decide to exceed the M values. This can be done if the ED machining is
not deep, the quality of the final surface is not decisive and if the electrode is made of graphite.
With a copper electrode, it is necessary to be more careful as the tendency of copper to expand
must be taken into account.
Not to be underestimated is a possible programming of too sensitive control units.
If the undersize is sufficiently large but the surface of the electrode small, the checking limits
given in the table may be exceeded. How-ever, the fact has to be taken into consideration that
overcharging an electrode increases the wear, especially with copper electrodes; this may be
counterproductive. It becomes necessary to increase the parameter P (pause) and reduce the
parameter C (compression) and possibly reduce the timer EDM time.

After the change of electrode

If the loss of time takes place with the first pulse of the second electrode, the following causes
may be considered:
1 There was machining with too much wear with the preceding electrode, thus it is necessary to
recover this wear.
2 The two electrodes are not precise and so this imprecision must be recovered with
supplementary ED machining.
3 The first pulse of the new electrode is too weak and the machine has difficulty in resuming ED
machining. You are therefore advised not to change with too weak pulses, rather make some
concession on the quality of the final roughness.

Finishing

The situation is tricky.

The cause is always the last pulse because it is always necessary to remove much material with
this, that is the difference between M and the GAP. It is with experience that you will succeed in
finding the best solution.

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Some advice:
• Check whether the roughness selected is really necessary or whether it can be slightly higher;
if it can, finish one or two pulses previously or instead of finishing on value GAP finish on
value M.
• If the surface is large, reduce parameter T in the final pulses, thus work with maximum removal;
there will be a little more wear, but on large surfaces that is difficult to quantify.
• Reduce the lateral and frontal compensation factor M for the semi-finishing and finishing
pulses.

2 Workpiece

See also “working Conditions”

2.1 Preparation of the Workpiece

2.1.1 Reference surfaces

The shape to be eroded must have a well-defined position with respect to other shapes or holes,
or with respect to other surfaces which must, for this reason, be precisely machined so as to
function as a reference. Generally, the reference is taken from two level and perpendicular
surfaces, or from a centering hole and a ground surface.

2.1.2 Flushing holes

Depending on the machining to be carried out (planning), it is necessary to make provision for
any flushing holes required which can be produced in the following ways:

● Untempered steel workpieces: Drill

● Tempered steel workpieces: Sink ED sinking with tubular electrode/ Drill with diamond point
● Hard metal workpieces: Sink ED sinking with tubular electrode/ Pre-sinter

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2.1.3 Tempering

The workpiece must be tempered before EDM because of possible torsion in material. On the
other hand, tempering dose not constitute a factor of any difficulty for EDM. If the tempering is
carried out in a brine bath, it is necessary to sandblast the workpiece or to grind always a
thickness of approximately 0.05 mm from the surface.

2.1.4 Clamping

The dimensions of the workpiece must be such as to allow it to be clamped to the work table or
the pallet. The weight of the workpiece plus the clamping mechanism must not exceed the
permissible table load.

Pre-alignment on a pre-rigging station permits a notable reduction in non-machining time for the
ED machine.

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2.2 Pre-machining of the workpiece

Purpose: Reduction of the material to be removed, i.e. of the machining time.

Milling cutter
Electrode

premachined contour
finished contur

Advantages
[1] less wear
[2] possibly fewer electrodes
[3] Simpler heat treatment
[4] Weaker roughing currents mean that the eroded surfaces are less affected by heat.

Disadvantages
[1] In the absence of a universal clamping system, the workpiece must be clamped several
times during preparatory machining using conventional systems.
[2] Danger of milling tracks on the electrode and thus also on the finished workpiece.
[3] Machining starts with low settings, thus less metal removal and more wear.
[4] Stability problems during the start period.

Electrode

milling cutter

surface of the
workpiece after
preparatory milling tracks
surface of the
finished workpiece

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3 Electrodes

3.1 Impulse Selection and Application

Impulse selection determines both the electrode production and the erosion process. The form to
be eroded, in turn, is a determining factor in impulse selection.

1 Cylindrical forms: Forms

with perfectly vertical 1 2

lateral surfaces.

2 Conical forms: Forms with angled lateral surfaces.

Select the technology and plan the erosion process according to the following diagram:

Impulse Fp M 2 Gap K
2
number cm mm mm (POS)
Finishing: VDI (K)

Roughing：Fp cm2

Select impulse number

Electrode planning
Electrode To input all impulse data
Undersize for roughing electrode
production parameters
Undersize for finishing electrode

Erosion step

Erosion
Erosion impulse
number

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● Impulse selection （without using the planetary）

For the impulse selection, Cylindrical forms and Conical forms are the same :

[1] Roughing impulse (first impulse)

Selected as a function of the erosion surface Fp(cm2). The “Safe 2 GAP” value of this impulse
is to be taken into account when defining the undersize with which the roughing electrode is to be
manufactured.

[2] Finishing impulse (last impulse)

This is selected according to the desired roughness (Ra). The “2 GAP”of this impulse must be
taken into account when determining the undersize with which the finishing electrode is to be
manufactured.

[3] Intermediate impulses (possible third electrode)

If the difference of the roughness Ra of the finishing and the roughing impulse exceeds a factor of
4, one or possibly more intermediate impulses may be selected. The difference in Ra between
two successive impulses should not exceed the factor of 4.
But for the Conical forms, there is a special case: Difficult-to-produce electrodes or forms of
large dimensions.

The number of difficult-to-produce electrodes can be reduced thanks to the advantages of

eroding conical forms:
- Better flushing compared to the cylindrical forms: A more stable erosion process

- Possibility of using more impulses with the same electrode given the lateral erosion.

● Pulse selection

[1] First roughing pulse: First roughing pulse is selected as a function of the erosion surface
area (Fp cm2).
[2] Last finishing pulse: This is selected according to the desired roughness (Ra). The 2 Gap of
this pulse must be taken into account when defining the undersize with which the finishing
electrode is to be manufactured.
[3] Intermediate pulses: All the intermediate pulses （between the first and last impulse）can be
used . They are arranged in definited order (from the largest to the smallest).

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● Impulse selection （Using the planetary）

[1] First roughing pulse: First roughing pulse is selected as a function of the erosion surface area
(Fp cm2).
[2] Last finishing pulse: This is selected according to the desired roughness (Ra). The 2 Gap of
this pulse must be taken into account when defining the undersize with which the finishing
electrode is to be manufactured.
[3] Intermediate pulses: All the intermediate pulses （between the first and last impulse）can be
used . They are arranged in definited order (from the largest to the smallest).

3.1.1 General Impulse Characteristics

Normally, it is not possible to attain the desired surface finish with the roughing impulse setting. It
is therefore necessary to select technology for the finishing impulse that allows a finer surface
finish to be obtained. The erosion process begins with the roughing impulse settings (for
large-scale removal) yet leaving enough material on the sides and bottom of cavity to produce the
desired surface with the finishing impulse settings.

Roughing impulse (▽) Large-scale removal

-Rough surface finish
-Large gap
Large gap
-Large-scale removal
Rough surface finish

Small-scale removal
Finishing impulse (▽▽▽)
-Fine surface finish
Small gap
-Small gap
Fine surface finish
-Small-scale removal

The impulse used for erosion contain a ‘Safe 2 GAP’ value (for the roughing electrodes) and a “2
GAP” value (for the finishing electrodes).

The finishing impulse produces a smaller gap; therefore, during erosion with a vertical movement
only, it is necessary to use various electrodes with differing undersizes (see also “Determining the
Undersize” later in this chapter).

The depths of erosion will also be different for each pulse used.

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Smaller erosion depth

Large undersize

Roughing electrode (▽)

-Large undersize
-Smaller erosion depth

Small undersize
Large erosion depth

Finishing electrode(▽▽▽)
-Small undersize
-Large erosion depth

Adapting the Roughing Impulse to the Erosion Surfaces

By using stepped or conical electrodes, the erosion surface area (Fp cm2) will vary during
roughing depending on the erosion depth. There will thus be more roughing impulses.

First impulse Second impulse Third impulse

Stepped
electrodes

Fp 1 Fp 2 Fp 3

Very conical
electrodes

Fp 1 Fp 2 Fp 3

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3.2 Electrode Planning

The following procedure is valid for use without planetary. If using planetary electrodes may have
the same undersize which must at least correspond with the roughing electrode. The gap
difference will be compensated by the planetary movement.

3.2.1 Determining the electrode material

The range of applications for graphites in the machining of steel is becoming ever more important
for fine working as well. (ease of electrode construction minor thermal deformation, greater
removal).

Copper
All indications in the corresponding technology tables refer to electrolytical copper.

Tungsten copper
All indications in the corresponding technology tables refer to tungsten copper of the quality

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75%W, 25%Cu. Other qualities can cause slight variations of the values for removal rate and
relative wear.

Graphite
On the market a great variety of different graphite qualities can be found, offered by several
manufacturers and suppliers. With regard to their characteristic physical parameters, these
graphite types can be assigned to different groups, according to their preferential field of
application. The values contained in the following tables are indicative and represent only a
guideline. All indications in the corresponding technology tables for fine graphite refer to
graphites of the graphite class 1. (Graphite class 1 corresponds to graphite 1 in Tectron (cycle
that automatically optimises the EDM process) All indications in the corresponding technology
tables for normal graphite refer to graphites of the graphite classes 2 to 4. Graphite classes 2 to
4 correspond to graphite 2 in Tectron.

Physical properties of the graphite classes

Graphite class
Physical parameter Unit 1 2 3 4
Density [g/cm3] > 1,83 1,8 - 1,78 - < 1,78
1,85 1,85
Grain [µm] <3 5 - 10 10 - 15 > 15
Hardness [Shore] >70 65 - 80 55 - 65 < 55
2
Flectional [N/mm ] > 80 50 - 80 40 - 60 < 60
resistance
Electric resistance [µΩm] > 15 14 - 20 10 - 15 < 15

Application fields of the different graphite types

Parameter Graphite class

1 2 3 4
Removal rate −− − + ++
Wear ++ + − −−
Surface quality ++ + − −−
Highly defined shapes ++ + − −−

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Recommended material pairing

Workpiece material

Electrode
Steel Hard Metal
material
Copper All uses All uses
Fine graphite for fine surfaces
(Rz < 20 µm)
Normal graphite for large electrodes
and rough surfaces
(Rz >20 µm)
Tungsten copper Fine working All uses
Tungsten Fine working Fine working
Steel Large tools
Post-processing of
surfaces

3.2.2 Determining the number of electrodes

● Cylindrical forms
Without planetary With planetary

Ra impulse ▽ =Ra▽▽▽: 1 electrode 1 electrode

Ra impulse ▽ ≤Ra▽▽▽×4: 2 electrodes 1 electrode

Ra impulse ▽ ＞Ra▽▽▽×4: 3 electrodes 2 electrodes

● Conical forms
Ra impulse ▽ ≤Ra▽▽▽×4: 1 electrode
In other cases: 2 electrodes

Apart from the rules described above, for very deep forms it is necessary to take into account the
deformation of the electrode caused by wear.

3.2.3 Determining the Electrode Tolerances

Accurate electrodes are indispensable for producing precision workpiece. Also, due to the
influences of environment, system and operators, the workpiece is always less accurate than the
electrode with which it is produced. Normally the electrode tolerance is half that of the workpiece
tolerance.

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Finishing electrode tolerance = workpiece tolerance / 2

Roughing electrode tolerance: This can be greater than the tolerance of the finishing electrode:
preferable on the minus side(-).

The positioning error is largely dependent on the clamping system and of course also on the
electrode manufacture.

3.2.4 Determining Undersizes [Safe 2 Gap (M) and 2 Gap]

Undersize and 2Gap

Undersize

The undersize is the difference in dimension

between the electrode and the shape to be eroded.

Undersize = b − a

Lateral Gap
Lateral Gap Gap

This is the spark gap, that is to say the distance

between the electrode and the workpiece in which
the discharge occurs. The frontal Gap differs from
Frontal the lateral Gap.
Gap
Frontal Gap: is exactly the distance between two
extreme points of the spark and is measurable. It
depends on the parameters T and I.

Lateral Gap: is approx. 80% of the frontal Gap. It

is an estimate based on experience.

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The undersize M

This is given by:

• 2 Gap
• twice the lateral roughness
• twice the safety margin
½ lateral M is approx. 80% of ½ frontal M. Laterally the discharge is less strong.

Safety margin

Roughness
GAP
½M

Standard undersizes

To facilitate the production of electrodes, it is

expedient to select the same undersize for both the
roughing electrode and the finishing electrode.
The gap difference will be compensated by the
Measure to be reached
planetary movement. This however will result in an
increase of the generated radii.
In this case, it is necessary to manufacture the
electrodes with undersizes corresponding exactly
to the values M for roughing and twice the gap size for
finishing respectively.

Correct selection of the undersize (M) is vital for successful erosion.

The tables of technology on board machine give the ideal undersize for each roughing impulse.
When using AEP, after inputting the correlative information in page “Process data” and
“Impulse” ,the value of the item “”Rec. undersize” appears. The electrodes should be
produced according to this value, and then enter the exact undersize value of the
electrodes in the area “Act. undersize”.

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If the electrodes have been manufactured, simply input the actual undersize of the
electrodes. An undersize below the specified one, would cause the generator to select a current
lower than the one which could be used, with consequent increase in erosion time.
An undersize higher the specified one does not lead to contrary indications as it is compensated
by the use of the planetary strategy.

Note : For AEP, the system will determine the number of electrodes and the undersize

automatically according to the information you provided Of course , you can change it
manually if necessary.

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3.2.5 Determining the material allowances

● Thermal expansion difference

[1] Machining copper-steel

When machining copper-steel, the heat expansion difference between the electrode and
workpiece materials can give rise to form errors: because of the higher heat expansion of copper,
there is the risk that the roughing electrode performs too large a shape so that there isn’t any or
too little material left for finishing. The average difference in thermal expansion coefficients
between copper and steel is approx. 4.5 µm/m℃

[2] Machining graphite-steel

The thermal expansion of graphite can practically be ignored so that only the expansion of steel
has to be taken into consideration.

Caution: When calculating the graphite electrodes undersize, the expansion of steel

has to be deducted.

● Re-machining allowance
If the workpiece is e.g., to be polished after erosion, than the material removed during this

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operation must be taken into account.

[1] Machining of steel:

Material allowance for polishing = 3 finishing roughness Rmax
[2] Machining of carbide metal:
Material allowance for polishing = 5 finishing roughness Rmax

3.2.6 Determining the final undersize

The following procedure is valid for use without planetary. If using planetary all electrodes may
have the same undersize which must at least correspond to the roughing electrode.

● Roughing electrode(s)

Safe 2 GAP
+ Positioning error
±Thermal expansion(difference)
+ Re-machining allowance
= Definitive roughing undersize

● Finishing electrode

2 Gap

＋ Re-machining allowance

= Definitive finishing undersize

3.3 Manufacture of electrodes

Manufacture of the electrode and EDM with a single clamping system.

It is very practical to manufacture the electrode (electrodes) already mounted on the clamping
system to be used for EDM, possible fitting, if necessary, any flushing accessories required. In
this way any errors in positioning due to dismantling and refitting on various systems will be
avoided.

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3.3.1 Machining by chip removal

The most frequently used methods are milling,

turning, as well as surface and cylindrical grinding.

● Milling by numerical control

This is preferable to conventional milling: more rapid and

completely automated, CNC milling permits great accuracy
reproduction (useful for the manufacture of more
electrodes) and also allows more complex shapes to be
obtained.

● Profile milling

This lends itself very well for the production of more electrodes for
the machining of tools for punching and molding. If the model is
constructed without taking account of the undersizes, these are
obtained with the correct choice of the tracer of the profile miller.

3.3.2 EDMing

Electrical discharge cutting can be useful for machining electrodes.

If electrodes of various undersizes are necessary, these can:

[1] be cut to the respective dimensions, or otherwise:

[2] be cut (possibly as a stack) to the undersize of the finishing electrode: in a second phase
the roughing electrode will be reduced in size by acid treatment.

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The combination of ED cutting and sinking makes it possible to avoid having to assemble
punches from components. This simplifies assembly operations and sometimes makes smaller
tools possible.

Punch

Machining by inversion

This is the name given to the manufacture of an electrode by means of another electrode and
prove useful for anyone not, having an ED cutting machine available.
The manufacture of the starting electrodes (usually positive ones) is carried out using
conventional methods.

3 electrodes (negative)

Finished tool

2 guide plates

1 die

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3.3.3 Hot pressing

By using new presses already available, it is possible to hot-work electrodes by means of a

hammer suitable for the purpose. This method of manufacturing copper electrodes is very rapid,
but one should not forget the time taken for heating, possible reduction in acid and positioning on
the electrode holders. The piece of copper must be heated to a temperature of 75℃(167°F),
possibly in an inert gas oven.

At the end of operation, eliminate the slag due to the heating by immersing the electrode
obtained in water, and finally sandblast it or wash it in nitric acid.

In order to let the electrode take on its exact form, strike it with a calibrated hammer working at a
temperature of 25℃(77°F), lubricating the press with molybdenum sulfide.

In order to produce the holes for fixing to the electrode holder, you are recommended to use the
press as a support, starting from the reference angle and following the system of coordinates.

In this operation, bear in mind that positioning errors increase the finishing time. The roughing
and semifinishing electrodes are reduced with nitric acid.

3.3.4 Galvanizing

Galvanoplastic methods are of interest for the manufacture of electrodes of large dimensions,
employed especially in the field of sheet molding.

The ED properties of an electrode manufactured in this way are very good.

Given the properties of the galvanizing process, it dose not lend itself for prominent contours,
and it is also important to bear in mind the differences in thickness of the material deposited and
the long duration of the manufacturing process. A negative is produced from the positive with
melted resin (e.g., Araldite). By means of a brush, a spray or immersion, the negative is given an
electrically conducting coating (liquid lacquer with minute particles of silver).

After these operations, it is passed on to the galvanic bath proper.

3.3.5 Abrasions

Graphite electrodes made using the abrasive system are suitable for presses for injection and
forging, for small and large series.
Reworking of the electrodes is very simple and rapid. The abrasive tool (negative) of synthetic

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material must be produced taking account of the planetary movement.

Tool in synthetic material

Abrasive layer

Graphite workpiece (electrode)

Planetary movement

3.3.6 Sectioning the electrodes

When a form to be eroded contains many different particularities, it is advantageous to produce a

number of individual electrodes in order that each one is suitable to erode its own particular part
of the whole. This naturally facilitates the production of the electrodes and also the erosion
process.

1 Large stock removal zones

2 Different roughness
3 Different forward directions
4 Large volume differences
5 Difficult working particulars
6 Complex details
7 Form combinations

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4 Precision

4.1 Environmental influences

Caution:
The system should not be exposed to the direct rays of the sun or to draughts. Variations
in temperature should be monitored, and the use of an air-conditioning plant is
recommended.

Influence of room temperature variations on longitudinal dimensions:

a) Influence on dimensions
b) Influence on position
c) Influence on shape

4.2 Influences due to the system

See delivery report.

4.3 Human influences

Size and quality of the stops and → position error

clamping surfaces
Chosen processing technique → shape errors

Alignment error in relation to machine → ≤ 0.01 mm

axes (parallelity)
Sensing error (positioning uncertainty) → ≤ 0.004 mm

Positioning error → ≤ 0.006 mm

GAP- width uncertainty (approximate

→ ≤ 0.005 mm
values)
Servicing → position and shape errors

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Roughness designations

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After treatment

● Micro-blasting

To execute in two steps:

Step 1: Cleaning the surface by removing the white layer without affecting the basic structure.

Step 2: Surface compression and roughness reduction.

Distance Pistol/Piece: 20...60 mm

Blasting angle: 0...60°from the vertical

Blasting time: 2～3s/cm2 ，Till the surface is clean.

Unit: bar
Ra≤1µm Ra＞1µm

Steps of microblasting Step1 Step2 Step1 Step2

Material MICRONORM MS 300A MS 550B MS 300A MS 550B
Untempered steel 1.5...2 1...2.5 1...1.5 0.5...1.5
Tempered steel 1.5...2.5 1.5...3 0.5...1.5 1...2
Tungsten carbide (coarse grained) 1...2.5 1...2 0.5...1 0.5...1.5
Tungsten carbide (fine grained) 0.5...1 0.7...1.5 0.5...1 0.5...1.5

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5 Impulse introduction

5.1 Impulse Data 1

The following parameters cannot be changed without changing the overcut and finish specified in
the technology charts.
• Polarity (Pol)
• Peak current (I)
• On time (T)
• C
If you change any of these parameters, the M and 2G values and the impulse number turn red to
warn you not to expect the specified overcut and finish.

The list below gives a brief description of the Erosion parameters. Terms in bold type are
displayed on the Impulse Data panel if “Parameter Display” on the Configuration/User Interface
page is set to “Long”. Alternate terms in parentheses display if “Parameter display” is set to
"Short". Refer to section “Parameter Display” in Chapter 4.

Off Time (P): 0.4…514000 (µS): Time between two cutting pulses during which no current flows.

Compression (Comp): 0…100(%): The erosion gap spacing. With a higher compression, the
servo moves the electrode closer to the workpiece.

Gain: 0…255(pos): This is the velocity gain of the servo system during erosion.

Volts (U): Open gap voltage (0~300 )V

ACC: Automatic process adjustment that provides some DC arc protection. The value is the
sum of the values of each condition selected. Click the box next to the desired ACC condition.
Example: ACC5 means ACC1=on; ACC2 = off; ACC4 = on, ACC8 = off.

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ACC 1 Turn off spark that tends to become arcs.

ACC 2 Command a timer movement if ACC1 turn off too many sparks.
Command a timer if there is too resistant discharges and voltage during off timer
ACC 4
is low.
Turn off spark on which the open voltage did not reach a minimum value (tend to
ACC 8
arcing).
ACC16 In case of ACC8 intervention it introduce a longer off time (more security).
ACC32 Same as ACC16 but introduce a smaller off time.

ACC functions that are not available cannot be checked (not selectable.)
Important! Use ACC only for copper-steel and graphite-steel. Turn ACC off when using
any other material pairs.
Set ACC = 7 for roughing (first impulse) and ACC=5 for the rest of the job.

ACO: Automatic process tuning. Provides some DC arc protection. Its value is the sum of the
values of each feature selected. Click the box next to the desired ACO feature.

ACO is for use with all material combinations.

ACO 1 U goes to 250 if there is not sparks for 8ms.
Limit the gain at start and at the timer forward move (use with large
ACO 2
electrodes).
ACO 4 Adapt impulse to the projected area.
ACO 8 Adapt orbiting speed.
ACO 16 Generator off during all the timer movement.
ACO 32 Erosion time equal to real erosion time.
ACO 64 Time in unigap = time without move at the end of the vector.

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Capacitance (C): 0...127(pos), For use when ED machining of very small surfaces or very fine
roughness to add capacitance to erosion gap and allow more spark energy to be produced from
the same pulse. The Peak Current (I) must be less than 8.

C C C C C C C C C C C C
pos nF pos nF pos nF pos nF pos nF pos nF
0 0.00 22 5.90 44 12.73 66 33.00 88 540.00 110 941.00
1 0.10 23 6.03 45 13.20 67 48.00 89 555.00 111 956.00
2 0.20 24 6.23 46 13.40 68 68.00 90 573.00 112 1020.00
3 0.33 25 6.90 47 13.53 69 83.00 91 588.00 113 1035.00
4 0.53 26 7.10 48 13.73 70 101.00 92 608.00 114 1053.00
5 1.00 27 7.23 49 14.70 71 116.00 93 623.00 115 1068.00
6 1.20 28 7.43 50 14.90 72 180.00 94 641.00 116 1088.00
7 1.33 29 7.90 51 15.03 73 195.00 95 656.00 117 1103.00
8 1.53 30 8.10 52 15.23 74 213.00 96 660.00 118 1121.00
9 2.20 31 8.23 53 15.70 75 228.00 97 675.00 119 1136.00
10 2.40 32 8.43 54 15.90 76 248.00 98 693.00 120 1200.00
11 2.53 33 10.00 55 16.03 77 263.00 99 708.00 121 1215.00
12 2.73 34 10.20 56 16.23 78 281.00 100 728.00 122 1233.00
13 3.20 35 10.33 57 16.90 79 296.00 101 743.00 123 1248.00
14 3.40 36 10.53 58 17.10 80 360.00 102 761.00 124 1268.00
15 3.53 37 11.00 59 17.23 81 375.00 103 776.00 125 1283.00
16 3.73 38 11.20 60 17.43 82 393.00 104 840.00 126 1301.00
17 4.70 39 11.33 61 17.90 83 408.00 105 855.00 127 1316.00
18 4.90 40 11.53 62 18.10 84 428.00 106 873.00
19 5.03 41 12.20 63 18.23 85 443.00 107 888.00
20 5.23 42 12.40 64 18.43 86 461.00 108 908.00
21 5.70 43 12.53 65 15.00 87 476.00 109 923.00

Polarity (Pol): + / - Selects the electrical polarity of the electrode.

Elect. Pos. Ram / Table: Selects the location of the electrode.
Cycle Timer: On / Process / Off On: If ACC2 is off the electrode moves away from the
workpiece at regular intervals set by the Erosion Time. If ACC2 is on reciprocation is a mix
between the fixed interval and process-controlled timers.
Process: Process controlled timers (ACC2 must be on).
Off: No cycle timers.
Erosion Time: 0.1...32 (sec.): Cycle Timer must be "On". The duration of erosion between
retracts.

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Timer Speed: Cycle Timer must be "On" or "Process". The timer speed sets the relative
velocity of withdrawal during a cycle timer. The equivalent values are given in the table below.
Speed Speed Speed
position mm/s mm/min
1 0.6 36
2 1.2 72
3 1.8 1.8
4 2.4 144
5 3.2 192
6 4.8 288
7 7.4 444
8 11.2 672
9 17.4 1044
10 24.4 1464

Retract Dist: Cycle Timer must be "On" or "Process". This sets the timer withdrawal distance.
When a Retract Distance of 0 is input, the number changes to ‘Auto’ (Automatic cycle timer).
When the ‘Retract Distance’ field reads ‘Auto’, the cycle timers are adapted as a function of depth
and Work Type (Application).

If a fixed Retract Distance is required, just insert the distance into the Retract Distance field. This
action disables the Automatic Timer Adaptation.

5.2 Impulse Data 2

Mode. The Mode parameter allows you to modify the form of the current pulse. The forms
presented here are implemented. This parameter can only be changed in the user database.

Mode 0

Mode 3

With the form MODE 3 the electrode wear is lower compared to MODE 0.

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Osc. Mode (OM): Oscillator Mode. This parameter can only be changed in the user database.
0 = ISO Frequency.
3 = ISO Pulse.

Servo Mode (SM): Mode of operation for the servo. Its value is the sum of the values of each
feature selected. This parameter can only be changed in the user database.
The servo uses a proportional regulator to adjust the position by looking at the
SM 0
delay (time to discharge).
The servo regulates the position by comparing the compression, not with the
delay, but with the average gap voltage. The higher the compression, the
SM 1 more the regulator tends to approach the electrode to the workpiece. As a
result, the average voltage is smaller. This mode is useful with capacitance
where the delay is not so significant.
The servo uses a fuzzy logic regulator. The positioning is done by comparing
SM 2 the compression either with the delay or with the average current, depending
on the state of SM 1.

Frontal Area (Fp): A measure of the surface (cm2) machined with the face of the electrode.
This surface is perpendicular to, or nearly perpendicular to, the machining direction. This
parameter can only be changed in the user database.

Removal Rate (Vw): The volume per minute (mm3/min.) of workpiece material eroded during

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the EDM process. This parameter can only be changed in the user database.
Wear (Theta): The percent of volume of electrode worn away during the EDM process. This
parameter can only be changed in the user database.

VDI Class (K): The measure of the surface finish. VDI 3400 class. This parameter can only
be changed in the user database.

M: Undersize M. The “M” value has been calculated from the double spark gap 2G, twice the
surface roughness of the chosen impulse and a safety margin. For frontal compensation, only
M/2 is used (see "Determining the undersize M and 2 Gap"). This parameter can only be
changed in the user database.
2G: Undersize 2 Gap. The “2G” value is the double spark gap of the last erosion pass. For
frontal compensation, only G is used (see "Determining the undersize M and 2 Gap"). This
parameter can only be changed in the user database.

5.3 Influence of the parameters

5.3.1 Principal parameters

When preparing a job it is necessary to take care to utilise optimum parameters in order to
reduce both the cycle times and the production costs to the minimum possible.
The parameters T (pulse length), U (no-load voltage) and I (pulse intensity) are three very
important parameters in the EDM process.
These parameters cannot be changed without changing the overcut and finish specified in the
technology charts. Any modification to them during the job may compromise the final result.

T (pulse length)

T The pulse length has an influence on the Gap (distance

between the electrode and workpiece), on the removal and

I on the wear of the electrode. The longer the pulse, the

greater the Gap becomes, the wear of the electrode and the
removal are reduced, the roughness increases. The shorter
the pulse, the smaller the Gap becomes, the wear of the electrode and the removal increase, the
roughness diminishes.

Attention: the reference values roughness and undersize of the technological table,
chosen in order to execute the job, will no longer correspond if the value of parameter T
has been modified.

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U (idle voltage)

In the discharge channel, present before the

U beginning of the discharge. The higher the value of U
is, the larger the electrode-workpiece distance (Gap)
becomes, improving the flushing conditions as a
result. This parameter should also be used as the optimisation parameter.

I (current intensity)
The parameter I (current intensity) corresponds to the number of amps loaded on the electrode.
The higher the parameter, the greater the Gap becomes and the rougher the workpiece becomes.
The smaller the parameter, the smaller the Gap becomes and the less rough the workpiece
becomes.

Attention: the reference values roughness and undersize of the technological table,
chosen in order to execute the job, will no longer correspond if the value of parameter I
has been modified.

5.3.2 Optimisation parameters

As ED machining is a dynamic process, the optimisation parameters arrange which quantities

can be adapted in order to improve EDM conditions.
The three parameters, Timer, Pause and Compression are the main parameters for optimisation.
There are also other optimisation parameters: Gain (reaction of the servo), U value (no-load
voltage). They are secondary parameters.

Timer
Is the main optimisation parameter to be used when not working
in optimal conditions (without central flushing).
The movement of the timer keeps the dielectric clean between
the electrode and the workpiece. The timer practically replaces
central flushing.
The first operation to be carried out is to insert the Timer,
keying in a very short EDM time (0.5 seconds). The speed of
the timer is very important, especially when there are
electrodes of large dimensions to be reduced. The reduction of the timer EDM time does not
necessarily increase the total machining time in that by improving the EDM conditions the fuses
will cut out less.

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Parameter P (pause)
Is the pause time between one pulse and the next. It is one of the
most important parameters in order to stabilise the erosion; has
no influence on the GAP and the roughness. The longer the
P
pause, the less dirty the dielectric becomes, but the removal is
reduced. With short pauses it is thus necessary to put the timer
into operation more frequently in order to assist the evacuation of the eroded particles from the
work area (Gap).
The pause has a direct influence on the machining time.
Theoretical example with a constant pulse (T = 50)
P 50 Machining time: 10 h.
P 100 Machining time: 20 h.
P 25 Machining time: 5 h.

Attention: by reducing the pause, the dirt in the GAP increases, thus the control units
(ACC, ACO) could cut out more frequently with a consequent increase in the EDM time.

Compression
Allows you to vary the distance between the electrode and
the workpiece. By reducing the compression, the distance
increases thus facilitating the evacuation of the sludge, but
the EDM is less efficient.
By increasing the compression, the distance diminishes and
the EDM becomes more efficient, but the evacuation of the
sludge becomes difficult, with consequent cut outs by the
control units (ACC, ACO).
Reduce the compression in case of:
• very difficult machining conditions
• fine but overloaded electrodes
• very deep ED machining with precarious flushing conditions

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6 Process Data

Start Distance: The distance to move in the direction opposite the cutting vector when the
erosion cycle stops. Cannot be a negative value. Click the data field to insert a value. The
value can be a variable.
Erosion Vector: The position to which the electrode will advance during the erosion step. If
an orbit is also selected for the erosion step, the orbit will start after reaching the end point of the
Erosion Vector.
Two different modes are available to describe the Erosion Vector:
1) The X/Y/Z/C vectors endpoint mode (shown).
2) The Distance/Angles mode.
Click the Mode button to toggle the Erosion Vector display from one mode to the other.

Select the mode for X/Y/Z/C vectors to enter values that describe the endpoint of the erosion.
X Vector From -1000 to 1000 mm (-40 to 40”) The relative distance in X from the start point.
The value can be a variable.
Y Vector From -1000 to 1000 mm (-40 to 40”) The relative distance in Y from the erosion start
point. The value can be a variable.
Z Vector From -1000 to 1000 mm (-40 to 40”) The relative distance in Z from the erosion start
point. The value can be a variable.
C Vector From -16,000° to 16,000°. The C vector value is the degrees in C from the start
point. The value can be a variable.
Select the mode for distance and angles to describe the erosion with the following values:
Distance: The length to erode. Can not be a negative value.
Vertical Angle: (0 to 360°) an angle off the Z axis, e.g., where 0° gives a –Z direction; a value of
90° results in no Z movement; and a value of 180° gives a +Z direction.
Horizontal Angle: (0 to 360°) the angle on the X/Y plane, e.g., where 0° gives a +X direction; a
value of 90° gives a +Y direction; a value of 180° gives an -X direction; and 270° gives a –Y
direction.

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Gap Compensate: M/ 2G / OFF. This is the type of overcut compensation for which the
machine must take into account in order to reach the exact workpiece dimension in Z, and also
laterally.
The system computes Gap compensation as follows:
Gap Compensation = OFF Z’ = Z R’ = R
Gap Compensation = M Z’ = Z- (1/2M) R’ = R- ((80%) (1/2M))
Gap Compensation = 2G Z’ = Z-G R’ = R- ((80%) (G))

Where:
Z’ = the erosion vector end point to which the machine actually erodes
Z = the programmed erosion vector end point (process data)
R’ = the radius to which the machine actually erodes
R = the programmed radius (orbit data)
For all impulses except the final one: Compensation M
For the final impulse: Compensation 2G
The values M and 2G are shown in the Impulse Data 2 panel.

Note：In order to balance machining surface and speed, the system use Surface

Integrity according to demand to adjust actual compensation of AEP.

Frontal Scale: 0 to 15000%. Adjust the frontal gap compensation as a percentage of the M or
2G value. Default = 100%. If you change the default value, the M and 2G values and the
impulse number turn red to warn you not to expect the specified overcut and finish. The value can
be a variable.

Lateral scale: 0 to 15000%. Adjust the lateral gap compensation as a percentage of the M or
2G value. Default = 80%. If you change the default value, the M and 2G values and the impulse
number turn red to warn you not to expect the specified overcut and finish. The value can be a
variable.

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Unigap: 0 = OFF, 1 - 3600 seconds. The Z axis continues erosion at Z depth (spark-out) until
the selected number of consecutive seconds have passed without a servo retract. Unigap is used
to improve the frontal roughness consistency.
C Rotate: Constant rotation can be turned on or off for each erosion step as desired. The
range of values is from -40 to 40 RPM (0=stationary).
When the Job program execution reaches an erosion step, the C axis will begin constant rotation
if the value for C Rotate is other than 0. Upon completion of the erosion step, C rotate turns off.

7 Screw Operation

Set the “erosion vector” on the Process Data panel to the point where
threads will begin.
Click the MODE button to select either CZ vector or Distance/threads
per inch (TPI).

Threaded
length

Pitch

For CZ vector:
Z vector = threaded length (always a signed (+/-) value)
C vector = the number of C axis rotations required (number of threads x 360°). Determine the
number of threads by dividing the threaded length by the thread pitch.

NOTE: Right hand thread must have a negative (-) C vector value.

For Distance/TPI (pitch):

Distance = threaded length (always a positive number)
TPI = threads per inch (inch mode)

NOTE: Right hand thread must have a positive TPI (Pitch) value.

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Inch example: ¼-20 thread screw ½” deep

Threaded length = 0.5
Number of threads (0.5/0.05) = 10
Rotations (10 x 360°) = 3600
Z vector = -0.5
C vector = -3600
Or
Distance = 0.5
TPI = 20

Metric example: 5mm x 0.85 screw 10mm deep

Threaded length = 10
Number of threads (10/0.85) = 11.76
Rotations (11.76 x 360°) = 4235.29 (round off to 4235)
Z vector = -10
C vector = -4235
Or
Distance = 10
Pitch = 0.850

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8 Abbreviations and symbols

Al Aluminum
Cu Copper (99.99% pure electrolytic copper)
F.Gr Fine graphite (POCO 3)
G 30 Carbide (30% tungsten)
Imp. Nr. Impulse number
M Undersize for roughing electrode(s)
N. Gr Normal graphite (POCO EDM 100, Ringsdorf EK 85, etc.)
St Steel (cold working steel)
Theta Volumetric electrode wear (%)
Ti Titanium
W Cu Tungsten-copper
2 Gap Undersize for finishing electrode
∇ Roughing operation
∇∇ Semifinishing operation
∇∇∇ Finishing operation

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Data, Impulse 1
Name Unit Field Description
BD Impulses [xxxxxx] Impulse code
I [A] 0.1 ~ 72/104 Peak current
T [µS] 0.4 ~ 514000 Discharge duration
P [µS] 0.4 ~ 514000 Pause duration
Comp [%] 0 ~ 100 Compression (percentage discharge delay)
Gain [pos] 0 ~ 255 Servo sensitivity
U [V] 0 ~ 300 Idle voltage
ACC [select] 1 ~ 128 Automatic process surveillance
ACO [select] 1 ~ 128 Automatic process optimization
ACCX [select] 1 ~ 128 Extension of ACC
ACOX [select] 1 ~ 128 Extension of ACX
MS [%] -5 ~ +5 Sensitivity ACC / ACO
S-Box [pos] 0 ~ 127 Setting of additional capacitors
POL [+/–] Electrode polarity
Cycle Timer [select] Off Timer off
Process Timer controlled ACC
On Timer on
Erosion [sec] 0.1 ~ 32 Erosion time of timer
Time
Timer Speed [pos] 1 ~ 10 Retraction speed of timer
Retract Dist. [mm] 0 ~ 25.4 Return length of timer

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9 Impulse Name

The impulse name is constructed by job requirements.

Impulse Name Definition by Position

Position 1 Xxxxxx Electrode material
Position 2 xXxxxx Workpiece material
Position 3 xxXxxx VDI 3400(Surface Finish) 1st Digit
Position 4 xxxXxx VDI 3400(Surface Finish) 2nd Digit
Position 5 xxxxXx Application
Position 6 xxxxxX Wear Priority Class

Positions 1 & 2: Electrode and Workpiece materials

Position 1 Electrode material Position 2 Workpiece material

(value) (value)
1 Graphite 1 grain size < 5 µm 1 Steel 1.2344 (AISI H-13)
2 Graphite 2 grain size > 10 µm & < 20 µm 2 Carbide (15% Cobalt)
3 Graphite 3 3 Aluminum
4 Copper (OFE 101) 4 Titanium
5 Copper Tungsten (25% copper) 5 Copper
6 Steel (hot forming tool steel) 6 Copper Base Alloy
7 Cast Iron 7 Nickel Base Alloy
8 Carbide 8 Cast Iron
9 Tungsten 9 (not used)

Positions 3 & 4: VDI 3400

Positions 3 and 4 contain the first and second digits of the VDI 3400 value for surface
finish (00 - 45). Refer to section 3 for the surface finish conversion chart.

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Position 5: Application

Standard Rib
Standard Rib Points
No Flush No Flush
xxxx1x xxxx2x xxxx3x xxxx4x xxxx5x

Position 6: Wear - Speed Priority

Very High
Very Low Wear Low Wear Standard Values High Speed
Speed
xxxxx1 xxxxx2 xxxxx3 xxxxx4 xxxxx5

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10 Surface Finish Conversion Chart

VDI Ra Aa VDI Ra Aa
3400 µm µin 3400 µm µin
00 0.1 4 23 1.4 56
01 0.112 4.48 24 1.6 64
02 0.126 5.04 25 1.8 72
03 0.14 5.6 26 2 80
04 0.16 6.4 27 2.2 88
05 0.18 7.2 28 2.5 100
06 0.2 8 29 2.8 112
07 0.22 8.8 30 3.2 128
08 0.25 10 31 3.5 140
09 0.28 11.2 32 4 160
10 0.32 12.8 33 4.5 180
11 0.35 14 34 5 200
12 0.4 16 35 5.6 224
13 0.45 18 36 6.3 252
14 0.5 20 37 7 280
15 0.56 22.4 38 8 320
16 0.63 25.2 39 9 360
17 0.7 28 40 10 400
18 0.8 32 41 11.2 448
19 0.9 36 42 12.6 504
20 1 40 43 14 560
21 1.12 44.8 44 16 640
22 1.26 50.4 45 18 720

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11 Setting guidelines

11.1 IMPORTANT NOTES!

□ If you set the Off Time (P) and Compression (Comp) parameters to values other than those
recommended in the following tables, the resulting removal rate (Vw) may differ from the listed
value.
□ Excessive flush pressure can cause variations in wear (Theta %) or M or 2G.
□ Technology was created under the following conditions:
• Round electrodes with central flushing through the Part.
• Copper Electrodes are 99.99% pure oxygen free copper
• Fine Grain Graphite Grain size < 5µm (POCO EDM - 1 - 3)
• Normal Graphite Grain size 10 - 20 µm (POCO EDM - 100 - 200)
• High quality tool steel
• IonoPlus Dielectric

11.2 Surface Finish Selection

Important: The indicated roughness may vary up to ±15% depending on:

• type of workpiece material
• type of electrode material
• flushing conditions
• surface area dimensions
• measuring equipment and procedures

11.3 Roughing Impulse Selection

2
Active Electrode Surface Fp (cm )
2
The active electrode surface area defines the impulse number with the maximum current per cm .
For electrodes with thin, sharp or pointed shape, you must select the first impulse with reduced
discharge current (smaller impulse number) or utilize the applicable ACO and ACC feature of the
machine to avoid electrode damage.

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