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Sinker EDM

We have 5 state-of-the-art Makino and Sodick precision EDM machines, meticulously designed to tackle your challenges in processing hard alloys and complex components. These high-end machines ensure ultra-high precision and exceptional processing efficiency, guaranteeing the perfect fulfillment of your precision parts manufacturing needs.Unleash Precision with Sundi’s EDM Services: Where Advanced Machinery Meets Expertise. Elevate Your Projects with Our Exceptional Quality, Swift Turnaround, and Competitive Rates, Ensuring Your Market Dominance.

What Is Sinker EDM

Sinker EDM is a specialized electrical discharge machining process. It uses a shaped electrode, often made of copper or graphite, submerged in an insulating fluid along with the workpiece. Electrical discharges occur between the electrode and the workpiece, eroding the material to create the desired shape. This method is ideal for making intricate cavities or complex shapes in conductive materials that are hard to machine traditionally.

In the manufacturing process, An electrical spark is created between an electrode and a workpiece, the temperature of the electric spark can reach 8000-12000 degrees Celsius, machines can carefully control the spark to affect the surface of the workpiece, the material is removed from the workpiece by series of repeated discharging to achieve the desired shape and dimension needs.

Sinker EDM is widely used in machining various materials with a very high melting point, excellent strength, and high toughness, such as tool steel, stainless steel, tungsten carbide and so more.

sinker edm
sinker edm

Why Choose Us for Sinker EDM

  • Advanced Technology

    We employ state-of-the-art sinker EDM machines that ensure high precision and intricate details.

  • Expertise and Experience

    Our team is capable of handling complex and delicate projects with utmost precision.

  • Customization Capabilities

    We specialize in creating custom electrodes to meet unique project requirements.

  • Quality and Precision

    we are committed to delivering projects within efficient timeframes without compromising on quality or precision.

  • Quality Assurance and Precision

    We adhere to strict quality control protocols and use precision measuring tools to ensure the accuracy and quality.

How Can We Operate and Control The Quality?

Operating and controlling the quality during Sinker EDM (Electrical Discharge Machining) involves a systematic approach to ensure precision and accuracy in the machining process.

  • 1

    Machine Calibration and Setup

    Before starting any EDM operation, the machine needs to be properly calibrated. This includes aligning the electrode and workpiece, setting the correct parameters, and ensuring the dielectric fluid is at the right level.

  • 2

    Electrode Selection

    Choose the appropriate electrode material (usually copper or graphite) and shape for the specific job. The electrode should match the desired geometry of the final workpiece.

  • 3

    Dielectric Fluid Management

    Maintain the dielectric fluid in the machine. It acts as an insulator and coolant during the EDM process. Regularly check and filter the dielectric fluid to ensure it remains in good condition.

  • 4

    Electrode Wear Monitoring

    During EDM, the electrode gradually wears down. Use monitoring systems to track electrode wear and replace it when necessary to maintain accuracy.

  • 5

    Toolpath Programming

    Develop a precise toolpath program that guides the electrode to erode the workpiece according to the desired design. Ensure the program accounts for electrode wear and compensates accordingly.

  • 6

    Quality Control Checks:

    Perform in-process quality control checks at specific intervals. This may include measuring workpiece dimensions, surface finish, and inspecting for defects.

  • 7

    Feedback Systems

    Utilize feedback systems that monitor the EDM process in real-time. These systems can adjust parameters on the fly to maintain accuracy and quality.

  • 8

    Finishing Operations:

    After EDM, additional finishing operations like polishing or grinding may be required to achieve the desired surface finish and tolerances.

  • 9

    Operator Training

    Ensure that operators are well-trained in Sinker EDM operations and quality control procedures. Skilled operators can make critical decisions during the machining process.

The Choice of Electrode Material

Electrodes play a crucial role in EDM, directly impacting machining quality and precision. Therefore, selecting the appropriate electrode material is essential for achieving desired results.

  • Copper

    Copper

    Copper is a common choice due to its excellent electrical conductivity. It allows for efficient electrical discharge machining (EDM) and is suitable for various workpiece materials.

  • Copper Tungsten Alloy

    Copper Tungsten Alloy

    Copper tungsten combines the conductivity of copper with the high melting point and wear resistance of tungsten. This alloy is suitable for EDM tasks involving high-temperature materials and challenging machining tasks.

  • Graphite

    Graphite

    Graphite electrodes are known for their high conductivity and wear resistance. They are often used for EDM applications involving hard materials and complex shapes.

  • Aluminum

    Aluminum

    Aluminum electrodes are used for specific applications, especially when EDMing aluminum workpieces. They are lightweight and suitable for certain special requirements.

  • Silver

    Silver

    Silver electrodes offer exceptional electrical conductivity and are employed for the precision machining of conductive materials.

  • Molybdenum

    Molybdenum

    Molybdenum electrodes are used in high-temperature EDM applications due to their high melting point and wear resistance.

Connect with the Sundi Tools Sales Team

Sundi Tools has decades years of experience in designing and precision fabrication with initial on-site consultation, Contact our sales team,you will get a quick reply.

The Benefits of Sinker EDM

Sinker EDM does not rely on mechanical strength and cutting force. It directly uses electrical and thermal energy to remove the extra material. This manufacturing process has the following benefits compared with the mechanical cutting process.

  1.  Suitable for machining various shapes and sizes of blind cavities.
  2. Extremely hard material machined which the traditional machining way can’t produce. And good tolerance is guaranteed.
  3. When machining the small parts, Sinker EDM can avoid damage from working pressure.
  4. Since there’s no contact between the workpiece and electrode, It greatly avoids distortion when machining the precision week and parts.
  5.  Excellent accuracy and surface finish control with great structural integrity.
  6. Automatic production can be processed.
  7. Improve reliability, greater consistency, repeatability, and efficiency

  8. Optimized the processing technology. Influenced by the material performance, some processes can be working after treatment.

Features and Description

The specific values can vary based on the EDM equipment used, the material being machined, and the specific setup and process parameters chosen. This table provides a general overview of what precision EDM can achieve.

FeatureDescription
Accuracy±0.005 mm to±0.015 mm(Typical)
Surface Roughness(Ra)0.1 to 1.6 μm(Depends on process parameters)
Surface FinishCan achieve mirror-like finishes
Complexity HandlingSuitable for complex geometries and intricate shapes
Material CompatibilityEffective for hard materials like titanium, hardened steel
Depth of CutUp to 300 mm (Varies based on machine capability)
Tolerance RangeTypically ±0.010 mm, finer tolerances achievable
Minimum Feature SizeAs small as 0.1 mm(Depending on electrode size)

Common Issues When Sinker EDM Processing

When processing with Sinker EDM (Electrical Discharge Machining), several common issues may arise. Addressing these challenges is key to maintaining efficiency and quality in the machining process:

  1. Electrode Wear: One of the primary issues in sinker EDM is electrode wear. Over time, the electrode erodes, which can affect the precision of the machined part. Managing and compensating for this wear is crucial to maintain accuracy.
  2. Inconsistent Surface Finish: Achieving a consistent surface finish can be challenging, especially when machining complex geometries or working with different materials. Surface finish can be affected by factors like discharge energy, electrode material, and dielectric fluid type.
  3. Inaccurate Machining Due to Poor Setup: Incorrect setup of the machine, including alignment and positioning of the electrode, can lead to inaccuracies in the machined part. Precision in setup is crucial for the success of the process.
  4. Difficulty in Machining Thin Walls: Sinker EDM can sometimes struggle with thin-walled features due to the risk of vibration or deformation during the process. Special care and advanced strategies are required to successfully machine these delicate structures.
  5. Material Removal Rate (MRR) Challenges: Balancing material removal rate with accuracy and surface finish is a common challenge. Higher MRR can lead to reduced accuracy and a rougher surface, requiring a trade-off based on the project requirements.
  6. Heat Affected Zone (HAZ): Sinker EDM produces a heat-affected zone around the machined area, which can alter the material properties. This needs to be considered, especially in precision applications.
  7. Debris Removal Issues: Efficient removal of debris (resulting from the EDM process) from the machining area is vital. Inadequate removal can affect machining quality and increase wear on the electrode.
  8. Dielectric Fluid Management: Maintaining the quality of the dielectric fluid is essential for efficient machining. Contaminated or degraded fluid can lead to poor machining results and increased electrode wear.
  9. Cost and Time Efficiency: Sinker EDM is generally more time-consuming and costly compared to other machining processes, particularly for larger volumes. Efficient process management is necessary to keep costs and time in check.
  10. Complex Programming and Operation: Programming for sinker EDM can be complex, especially for intricate shapes and deep cavities. Skilled operators with thorough knowledge of EDM programming and operation are essential.

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