Would really love to see more 3D printing/ EDM stuff on this channel. It's unusual and not something we see very often compared to normal milling/ turning etc
That moment at 8:41 beautifully shows one of the most challenges in wire EDM. You can't just cut huge chunk of material. Some parts are very challenging with internal stresses, parts will move slightly when cutting and removing material. You have to be smart with bridges you leave to cut the part off. On a machine with micron and smaller capabilities, this may be huge problem for some features. For this part in video, I think that it would be better to cut from side of the mounting plate to the right. Not that it matters, really, it was just to show the inside of the 3D printed part :)
That programme he showed did not finish that part, you could see how much the part moved. The 2nd and 3rd cut wouldn't of even done anything. He would of ran a second programme to clear up that face once it had moved. This happens all the time in unstable material. Something harder and more stable wouldn't of moved as much.
@@chrisdilz It's obvious it did not clean up anything as rough pass leaves max a few hundredths of a millimeter to remove in skim pass/passes. It's not just the material, it's about part geometry, how it was hold to the plate. Maybe if it was annealed it could help a little bit, but I don't think it would be much. Also, in the industry you can't just anneal something or make it from different material. You have to find a solution, if there is any.
@@spelunking4444 Well, it's not really anything that you measure before last pass. You would rather cut a piece of that material (that will be removed anyway) before and measure this and then adjust if needed and proceed to real cutting. Sometimes I just knew what dimensions will be, because it's very repeatable process. From data book, depending on your desired amount of passes, for example for 50mm heigh steel piece: •One roughing pass and one finishing wold be around 0,03mm for finishing pass. •One roughing and three finishing would leave just 0,001mm for last finishing pass.
@@thomasbarlow4223 The wire is . 010" not . 001" and why can't it be . 032" the part is only being cut to look inside. There's no specification for the cut other than being straight with a decent finish. Band saw and a belt sander. Done and you haven't finished a fixture yet
@@alexchandras5618 Even better, I use to use one for inspecting the heat treatment on a part. Cut it in half with the chop saw and polish it on the belt sander to check the depth of the case hardening.
EDM needs a better description than what it was given, so here goes: DI water does NOT allow current to pass through as he said, it specifically is a "dielectric", meaning it resists flow of current. What happens in EDM is that the high voltage breaks down the water in the electrode gap once the "dielectric constant" is exceeded. That is, once the voltage exceeds what the water can resist, an ablative arc forms and burns away a little bit of the target material as well as a much smaller bit of the tool. The accuracy of EDM comes from the short length and duration of said ablative arc. In modern wire EDM, there are hundreds of thousands of arc generated PER SECOND. They only reach a few thou, if that, away from the tool. Very neat stuff overall.
I do this every day, just on an older machine. And I love it. It's mega cool to see a newer machine and with an employee who is good at explaining what he's doing. And I love the 3D printed part. Cool 😀
I dont get it? I just hose down the tank every day and you just change the filters and swap the deionizing resin after a set amount of hours. Not exactly difficult?
EDM a part with to different geometric shapes on either end. When I was an apprentice in the early 90’s our shop EDM’d a testing clamp (heat treated) that utilized the block and cut out for destructive pull testing. It varied in shape and size one end to the other and with the slug split (EDM also) so when installed into the test rig the more pull force applied the greater the clamping pressure. I can’t recall the tolerance from end to end or angles involved but I do remember being amazed that such profiles could be cut to such accuracy. Thanks I’ll be looking forward to seeing what you have next.
Bad flushing 😂😆🤣 mines open flushing ie none submerged and when i have jobs where i have to have the Z high and cutting through cavities I get loads of dry spark issues, usually what titans do in machining blows my mind and have no experience with fancy cnc I do with edm wire 20+ years, with that part opening up with the stresses you should have cut from your jig to the end and leave a tab and then cut the base, I do stuff like this cutting into sections so they can be 3d scanned to make sure they are like what a cad model is supposed to be and to make sure the 3d printer is doing the features needed, It blows my mind when wire cutting a part open to find whats inside and the incredible detail. 👍👍👍
I was under the impression that the wire was not consumed, but I'm not very familiar with the process. I thought the wire only takes minimal damage and was rewound as the machine goes... Kind of like a bandsaw?
@@somethingelse4424 The wire is actually also eroded by the cutting action, so it has to be fed off of the new reel at the top to a waste bin that is usually at the back of the machine.
@@StevenHeins I see, so I assume you adjust the wire feed so that it is as slow as possible without being entirely eroded to the point of breaking? I guess you recover the brass, but I doubt the scrap value does much to offset the cost of new wire.
@@somethingelse4424 yes, it's a balancing act. There are servicing companies that are happy to take it, though it can get contaminated by the swarf from the cut
@@rhindy6846 I'm not the guy you asked the question, but heres how i got into it... I went for a CNC milling job but was told unfortunately one person came out on top... 3 weeks later they called me back and asked if i was interested in WEDM instead. I now run 4 WEDM machines, a EDM drill and a EDM Sinker. Ive just put a 6th axis into one of the WEDM machines too. I find it fascinating and the parts I make are so much more interesting than what I would of been milling.
@@chrisdilz thanks for the reply appreciate it. Where I live it seems to be you get put on a machine and that's your machine. I can work all the CNC lathes milling machines and borers but they have just kept me on the milling machine. Don't get me wrong I like milling the beat but would love to know how to work this EDM machines
@@rhindy6846 does your work have them? Tell them your interested! Shadow whoever ops them, cover their holidays? My work would be screwed if I left nobody else can run them, or use the cad software I use with them. One of the best things about Edm Is I no longer have to ask my wife to get metal splinters out my feet 😂
Love EDM and wire cut things, cutting almost daily. Love when the spark is clean and yeah when it gets it right. How long did that part took you to part it off? Curious of how fast latest things are.
Yea no mention of cut time is a glaring omission when discussing this kind of technology especially for the many viewers that have no idea how long EDM can take.
Good video. Could you guys do a solidworks or fusion tutorial on how to model that part? I gather the pipes would be a profile swept along a spiral/helix. How about the ribbing on the outside? This part is complex and it would be a great asset to us all if you could teach us how to model it. If so, it would be greatly appreciated. Have a good day.
The laser process obviously built in internal stresses. The software manu needs to add control over where the laser first and last melts. For example, melt on one side first, and subsequent passes will freeze and shrink, adding to stresses. If you were lasering a tube for example, and spiralled from the inside out, the outer runs will freeze and try to pull the work outward. If you can convince the software to start at center of tube thickness, and work outward in both radial directions, I believe the stresses would not conspire. I would be happy to brainstorm this issue with you guys, the machine builders, and the software designers...I work all three topics. You are awesome..well, actually, badass!! John
I love EDM.i make every day cuts for almost 20 years and never bored these machines...i think the part has big distance from upper and lower nozzle... this is speed issue!but you make an excellent cut!!
Could you try to improve the surface finish of the tube insides by running fine abrasives trough it like sandblasting? Maybe print tollerances to account for the material you need to remove
I've seen video from an Aussie foundry where they're sand-casting anvils. They break it out of the mold while it's still red-hot, and quench the anvil face to harden it, and then grind it flat. I'd love to see you take one of their rough castings, and then cut the face with EDM, since EDM doesn't care how hard the material is.
Just think that all this 3D printed stuff happened from a couple of us crazy dudes who took some old dot matrix printers and added extruder heads. Wild.
I feel the deionized water and how the machine cuts could have used a better explenation. He described distilled water, but didn't explain how the machine cuts or why it needs submerged in deionized fluid specifically. Just a thought.
The deionized water acts similar to the insulation on a copper wire, it focuses the electricity to only the wire and the part, thus making it possible to generate a spark powerful enough to cut through the metal while at the same time preventing that spark from creating an arc to the metal panels of the machine. If you touched the wire outside of that water while the machine was running, it would have enough energy to kill you. I hope that explains the process.
Always wanted to run wire EDM. We looked at buying a sinker EDM but decided to farm out the little EDM work we do. Awesome videos thanks for sharing!!! Also wear your safety glasses always and set a good example.
Titan, this is simply example, but if you show to produce plastic extrisuon tool - this is GREAT! ONA - the best. Easy to use, low price for parts. I think this better then Fanuc Robocut
The owner of my company bought some wire EDM machines 15 years ago because we were offloading the work. Nobody wanted to touch them. He asked me and I accepted the challenge. I love it. Bonus is he lets me recycle all the chopped-up wire. It's only about $5,000 every 4 months!! 3 machines run 24 hours a day when they are not getting PM done!
There is always some internal stress in metal. It's the most noticeable in long and thin parts, even when milling. It's especially true for hardened steels, which have a lot of internal stresses.
Did that for about 15 years. I had parts that we ran all the time holding holding +/- .000025. We checked the parts with go/no gages supplied by the customer. At one time Mitsubishi had about 70% market share. That is no longer the case!! Still good machines. Our shop had Fanuc and Mitsubishi!! Fanucs are a very good machine but not nearly as friendly as the Mits!!
I’d love to see something like this where you have a camera looking down the barrel as it were. So we can see the cut move away from us and the arcs moving.
That was totally sick to watch. Love the technology that is being invented these days. Seeing this video makes me wish I had my own machine shop where I could just run wild trying to invent things.
On the machine there are stickers. Wear gloves, eye protection, safety boots and wash your hands, danger of falling in, no pacemakers allowed. "I can actually put my hand in it no problem." The part gapes apart. Is that due to residual stresses from 3D printing or due to uneven clamping on the part holder?
Is your shop temperature controlled if working to 0.0001”. Also have you got your machine on a substantial isolation base from the main machine shop. If you are not doing this have you got local temperature sensing at the part on the cnc table?
Very cool and amazing. This type of part may not even be possible to make without 3D printing or hundreds of man hours of hands on fabrication. Instead the 3D printer did most of the work besides the set up and cad
I could be wrong but I don't think the reason you don't get shocked when putting your hand in the water has anything to do with the conductivity of the water. Rather, it has to do with the fact that compared to the metal that the current is passing through, your hand/body are very poor conductors. Current will flow through the path of least resistance.
Hi, Seeing that you have XY-control of the cutting in the end; would it be possible to do the cut again, but following the center of one of the pipes past the Y-split? (Sorry if this q.has allready been asked)
Trumpf machines a great when they are running properly. Good luck with service though. Every time I have had to deal with Trumpf service. It was a nightmare.
#VeryCool! #ThankYou! for keeping it positive. This video shows what is possible if we all try to get the best grades in school. Please in the next video give a shout out for all those who are coming up. By shooting out "YA HOOOOO!"
@@Nickle314 never cut printed parts myself but a bit of movement is normal to me with separating cuts. This looks quite a bit more open than I’m used to it with my parts.
These are invaluable in the Tool and Die industry, precision combined with the ability to cut hardened steel and even Tungsten carbide. Can make your guys running the cnc mill lazy though :), often if we have say 20 small parts with some simple features and an outer 2d shape you end up making a big block with all 20 in it then you just mill/drill the features and drill starting holes for the edm. So its just one big part in the mill move it to the edm and cut 20 complete parts out, no fixtures etc required. Its not really worth it for very large series since the edm is very slow.
3D Printing is still an open book technology, dependent on the material, plastic, alloy or low melt metal can be done with precision finish, other than that, still need precision deburring and coating to cover all those porosity...
I thought I was big shit flame cutting 2” steel , not so much. X&Y will never change.Amazing, water jet cutting was just entertaining my trade, this is way more interesting.
And Love you🤙🙏 In the US, 99% of small and large companies use Imperial. We have great respect for our Global audience though and in all machining videos we offer speeds, feeds and all parameters in both imperial and metric.
@@vuththiwattanathornkosithg5625 you mean published mechanical properties? There are a ton out there. You can start at the printer OEM sites. Velo3D, GE Additive, EOS, SLM. They all post them. I was in charge of 3d printing process control at an aerospace OEM before taking a role at a printer company and have probably seen 10000 tensile sample results in inconel 718 and 625, ti64, F357 aluminum, Haynes 282, SS316L, hastelloy X, etc. Unless something goes very wrong, the properties are much better than cast, but not quite wrought. Certain materials are obviously a challenge, but for the common materials, the properties are well established above cast properties. Some properties do have less data than others though
