Tech-Tip: Prevent EDM Canister Filter Leaks with Proper Lubrication

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Are you experiencing leakage from your EDM machine’s canister filter? Fortunately, there may be a very quick and simple, low-cost solution.

When replacing canister-style filters (outside-in filtration), it is important to lubricate the new filter O-rings on each end of the filter with a di-electric grease or petroleum jelly to prevent damaging or rolling of the O-ring. This is a process that can be easily overlooked during operator or maintenance personnel’s hectic schedules. If left unaddressed, however, the by-passing or leakage of the filter may result in damage to the machine.  As such, be sure to address the issue quickly to prevent any further, and potentially costlier, problems in the future.

EDMmatter Image 6-15-17

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A Q&A on Flush Cup Nozzles for Makino Wire EDMs (Part 2: PICO Round Guide Systems)

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In our last entry, we focused on the various nozzles and wear parts that are specifically designed for Makino’s Split V-Guide system. In part two of our response, we’re going to be looking at the part list associated with PICO (Round Guide) systems.

Sealed Nozzles (Good Flush)

  • Upper Head: PICO Guide
    • Nozzle Guard (Body) – Part #33EC085A418
    • Rubber Nozzle – Part #33EC085A711=1

EDMmatters Image1 6-8-17

  • Lower Head: PICO Guide
    • Nozzle Guard (Body) – Part #33EC095A422
    • Rubber Nozzle – Part #33EC095A718

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Detached Nozzles (Poor Flush)

  • Upper Head: PICO Guide
    • Nozzle Guard (Body) – Part #33EC085A419=1

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  • Lower Head: PICO Guide
    • Nozzle Guard (Body) – Part #33EC095A419=1

EDMmatters Image4 6-8-17

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A Q&A on Flush Cup Nozzles for Makino Wire EDMs (Part 1: Split V-Guide Systems)

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Q: What are the main types of flush cup nozzles and consumable wear parts for Makino wire EDMs?

A: Even simple questions sometimes require detailed answers. In this situation, the answer actually requires two responses as the part numbers vary between the Split V-Guide and PICO (Round Guide) systems that are available. Part one of this response covers the Split V-Guide system.

Sealed Nozzles (Good Flush)

  • Upper Head: Split Guide
    • Nozzle Guard (Body) – Part #18EC130B401
    • Inner Insulator Bushing – Part #20EC080A702
    • Nozzle Spacer – Part #18EC80A719
    • Rubber Nozzle – Part #18EC80A717
  • Lower Head: Split Guide
    • Nozzle Guard (Body) – Part #18EC130B401
    • Inner Insulator Bushing – Part #20EC080A702
    • Nozzle Spacer – Part #18EC130B705
    • Rubber Nozzle – Part #18EC130B706

EDMmatters Image1 6-1-17

Detached Nozzles (Poor Flush)

  • Upper Head: Split Guide
    • Nozzle Guard (Body) – Part #20EC920A401-01
    • Inner Insulator Bushing – Part #20EC920A701-00
  • Lower Head: Split Guide
    • Nozzle Guard (Body) – Part #20EC920A401-01
    • Inner Insulator Bushing – Part #20EC920A701-00

EDMmatters Image2 6-1-17

Taper Machining Nozzles (Poor Flush)

  • Upper Head: Split Guide
    • Nozzle Guard (Body) – Part #6EC80A418=2
    • Rubber Nozzle – Part #4EC80A708=1
  • Lower Head: Split Guide
    • Nozzle Guard (Body) – Part #6EC80A418=2
    • Rubber Nozzle – Part #4EC80A708=1

EDMmatters Image3 6-1-17

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What to Look for When Selecting a Magnetic Chuck for Sinker EDM

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When consulting EDM shops on work holding solutions, one question that we frequently receive is whether you can use standard magnetic chucks for EDM applications. Unfortunately, this is not the case. Magnetic chucks used in EDM machines are typically specialized for EDM applications. These chucks are sealed differently than magnetic chucks that are used for grinding machines, as the oil and debris from the EDM process can damage and seize-up the typical ON/OFF magnet levers. Several magnetic chuck manufacturers (such as Walker Magnetics, Suburban, Hermann Schmidt) offer EDM specific chucks that have fine pole divisions for improved work holding, magnetic poles that reach to the very edge of the chuck, and a more compact, thinner design to preserve the usable Z-axis stroke of the machine. Be sure that the magnetic chuck you purchase is designed and compatible for use on EDM machines.

EDMmatters 5-25-17

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A Q&A on EDAF Sinker EDM Electrode Discharge Dressing

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Q: Is there a way to perform discharge dressing of the electrode on a Makino EDAF3 machine?

A: Yes, the Hyper-i control does have a dedicated macro program for discharge dressing of electrodes, but the machine should be equipped with the high-speed C-axis spindle (MA C-Axis) and discharge dress macro. The discharge dressing process uses the machine to create its own electrode through the EDM erosion process. Creating small diameter electrodes is the most commonly performed function of EDM dressing, but this process can also be used to create shaped electrodes or remove worn sections of an electrode.

Discharge dressing starts with a larger diameter electrode that is then EDM’ed down to whatever diameter is needed using a dressing block that is setup within the work tank. Depending on the required electrode size, multiple steps can be dressed on the electrode to provide the best possible rigidity for the final diameter. Once an electrode diameter is dressed to size, it is then used to EDM the workpiece feature.

The dressing block can be made from pure tungsten, tungsten carbide, copper tungsten (CuW), or silver tungsten (AgW). The CuW and AgW materials typically provide the best results. The electrode material can be made from copper, tungsten carbide, pure tungsten, copper tungsten, or silver tungsten. Each electrode material type has slightly different characteristics that determine the amount of time that is required to discharge dress. Additionally, each material type provides varying degrees of rigidity for extremely small diameters, but AgW electrode materials are typically recommended for best results.

On the Hyper-i control, there is a dedicated Model Plan and G-Code function associated with the discharge dressing process.

G-code Function:

G105  O9020 N1 X___ Y___ Z___ R___ I___J___ T___ L___ A___ B___ M___

  • Main Functions:
    • X = X-Axis Start Point
    • Y = Y-Axis Start Point
    • Z = Target Dressing Length
    • R = Target Finish Diameter
    • I = Start Process Number
    • J = Finish Process Number
    • L = Dressing Direction [1 = -X (←) | 2 = -Y (↓) | 3 = +X (→) | 4 = +Y (↑)]
    • M = Spindle Rotation Speed (value of 15 is typically used)

EDMmatters Image1 5-1-17

EDMmatters Image2 5-1-17

For additional information, please refer to Chapter 12 in the Machining Techniques manual, or contact Makino Technical Support at 1-888-625-4664.

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