EDM drilling is a specialized tooling process that creates holes in metal parts and products by using electrical energy in the form of sparks to erode the metal. It is an alternative to conventional drilling methods when the material is too strong and resistant as it is an effective machining method for even hard materials such as polycrystalline diamond stock, magnet materials and carbide.
Also known as electrical discharge machining drilling, EDM drilling is accomplished one of two ways – ram EDM and small hole EDM, both of which use an electrode that shoots out electrical charge or sparks which are hot enough to erode away any metal. Holes can be made on curved and angular surfaces, and they are drilled quickly, with accuracy and completely straight. Any electrically conductive material may be drilled by this method, including aluminum, copper, steel, stainless steel, zinc, tin, titanium, gold, lead, silver, iron and bronze. Applications that make use of EDM drilling capabilities include for the creating of holes in turbine blades, fuel injectors, cutting tool coolant holes, hardened punch ejector holes, plastic mold vent holes and wire EDM starter holes which are necessary to start the process of wire cutting using electrical discharge machining. Precise and small holes are required in many different products and therefore EDM machining is used widely in the manufacturing, medical, automotive and aerospace industries.
The EDM drilling process begins with a round, hollow electrode made of brass or a similar metal, which then rotates around a spindle and shoots out electrical sparks that are extremely hot. The metal part or product is clamped down tight so it cannot move, and computer numeric controlled software determines the direction in which the electrode will point. A dielectric fluid bath, usually water based, is used to conduct the electrical current and to reduce the process temperature. It also washes away the eroded material debris and prevents any premature sparking which would result in an imprecise finish. When the electrical sparks, created by a servo-controlled generator, shoot out of the tip, an electric field is created in the gap between the electrode and metal work piece. The surface is slowly eroded by this electrical energy, forming microscopic pockets that eventually form a perfect hole. Hole diameters may be anywhere from 0.03 to 400 mm, and have the option to be extremely deep-up to 100 times the hole diameter. This is a key benefit in EDM drilling, as standard drilling is confined to depths 5 to 6 times the hole’s diameter. Those that drill long or large holes through hard materials are often equipped with an automatic electrode changer because they tend to wear out quickly. Though it is costly to replace the electrodes used, this process of EDM drilling is still a cost effective solution to many drilling needs.
Avon Broach and Production Company has been a leader in the broaching industry since 1950 and continue to lead the industry thanks to our commitment to customer satisfaction and our passion for the business. We pride ourselves on being able to tackle virtually any order from one piece orders to orders over a million pieces. We have over 5000 broaching tools in our inventory and we have over 75 broaching production machines. We are an ISO 9001:2008 registered company which means you can count on us to be your premium source for broaching.
We offer a great variety of broaching services and we will work with you to understand your process and application in order to provide you with the right form of broaching to ensure your final product is the product you need. Some of the broaching services we offer include: surface broaching, internal form broaching, internal cam form broaching, internal helical broaching, lock cylinder broaching, external pot broaching, turbine broaching and so much more. We couple our production orders with on time delivery to ensure you are getting the products you need.
Avon Broach has a 30,000 square foot manufacturing in Rochester Hills, Michigan and with over 60 years in the industry we are home to broaching experts who will be happy to assist you in making the right product for you. We take on virtually any order, there is a reason we have been a leader in the industry since 1950. We love working with our customers and finding out more about their specific applications. We do this in order to provide the best possible product that fits your specifications and will function properly in your application. Call us today or visit our website to find out even more about our company and see all the services Avon Broach offers.