ساخت دستگاه پالس EDM: نسل بعدی

Electrical Discharge Machining (EDM) is a process that uses electrical discharges emitted from an electrode to erode an electrically conductive material. As a result, it is possible to erode or “burn” the reverse shape of the electrode into the workpiece. Table of Contents Chapter 1 Introduction 1-1 I am in a Quandary 1-1 What do you Want in an EDM 1-2 It is More than a Power Supply 1-2 Some Inspiration 1-3 Chapter 2 A Little EDM History 2-1 Chapter 3 Overview of Mechanical & Electrical Components 3-1 Mechanical 3-1 Electrical 3-2 Chapter 4 The Power Supply 4-1 The Power Circuit 4-2 The Timer 4-2 Control and Motor Driver Circuit 4-3 How Does a Window Comparator Work? 4-4 Conditions at Startup 4-4 Short-Circuit Condition 4-4 What to Do When the Current Stops Flowing 4-5 The Peak Detector 4-5 Manual Up/Down and Dither Circuit 4-6 Chapter 5 Building the Power Supply 5-1 Soldering Tips 5-1 Construction Notes 5-2 Power-Supply Housing 5-3 Case Stiffeners 5-4 Front Panel & Power-Supply Layout 5-6 Power-Supply Layout 5-5 Major Components and Mounting 5-6 Wiring the High-Voltage Section 5-7 Power-Resistor Sizing and Mounting 5-8 Finish High-Voltage Wiring 5-11 PCB Location & Heat Sink Selection 5-12 Wiring the PCB 5-12 VII EDS Issues 5-12 PCB-to-Panel Connections 5-13 Chapter 6 The Servo 6-1 DC Gear Motor vs. Stepper 6-2 Servo Motor Selection for the Ram 6-2 The Lead Screw 6-3 Removing Shaft Endplay 6-3 Attaching the Lead Screw to the Gearmotor Shaft 6-3 Pin Method 6-3 Glue Method 6-4 The Slide 6-5 Slide Assembly 6-6 Final Slide Adjustment 6-6 Mounting Arm 6-7 Mounting Stud 6-7 Construction of the Head Bracket 6-8 Front Cover 6-10 The Finished Head 6-10 Head Wiring Options 6-11 Wiring the Head to the Power Supply 6-11 ON/OFF Motor Control 6-12 ON, OFF and UP limit Switch 6-12 ON, OFF, UP and DOWN Limit Switch 6-12 ON, OFF, UP, DOWN Limit and Depth-Control Switch 6-13 Chapter 7 Indexing 7-1 Indexer Chuck Overview 7-2 Indexer Chuck with no Metal Insert 7-2 Metal-Inserted Indexer Chuck 7-4 The Metal Insert 7-4 Misc. Indexer Chuck Photos 7-5 Electrode Manufacturing Fixture Block 7-6 Electrode Holders 7-7 The Squaring Tool 7-8 VIII Chapter 8 Depth Control 8-1 Chapter 9 Finish the Job 9-1 Building a Dedicated, or Add-on, EDM 9-1 Overview of the Work Tank and XY Movement 9-1 The Sherline Conversion 9-2 XY Tables and Selection 9-2 Chapter 10 Dielectric & Filter Selection 10-1 How Flammable is the Dielectric? 10-2 Dielectric & Materials Compatibility 10-2 Filters 10-3 Automotive Spin-on Filters 10-3 Automotive Filter Mounts/Filters 10-4 Diesel Filters 10-4 Water Filters 10-4 Filter Bags/Prefilter 10-4 5-Gallon Bucket Bags 10-5 Chapter 11 Tank & Pump Selection 11-1 Other Storage/Work Tank Options 11-1 Pump Selection 11-3 The Pump Dilemma 11-4 Submergible Pump 11-4 Non-submergible Pump Options 11-5 Chapter 12 The Back Slide 12-1 Frame Work Overview 12-2 Back Slide Rail 12-2 CRS WAYS 12-3 Tubular Frame Option 12-3 Wood Deck Option 12-4 Final Assembly of the Slide and WAYS 12-6 IX Chapter 13 Tank Assembly 13-1 Work Tank Support and Mounting Feet 13-1 Work Plate 13-2 Plumbing the Tanks 13-3 Dielectric Flow Control 13-5 Other Valve Options 13-6 Flexible Flushing Line 13-6 Variable-Speed Motor 13-7 Work Tank Dielectric Level Control 13-7 Pre-filter (Bag Filter) 13-7 Chapter 14 The Spark 14-1 What Happens in the Gap? 14-1 Duty Cycle 14-3 Frequency of the Spark 14-4 Metal Removal Rates 14-4 DC Arcing 14-5 Chapter 15 Electrodes 15-1 Factors Contributing to Reduced Electrode Wear 15-1 Electrode Polarity 15-2 Volumetric Wear 15-3 End Wear 15-3 Corner Wear 15-3 Electrode Wear Test 15-3 Overcut 15-4 Recast Layer 15-4 Electrode Materials 15-5 Metallic Electrodes in General 15-5 Brass 15-5 Copper 15-6 Copper/Silver Tungsten 15-6 Graphite Electrodes 15-7 Copper Graphite 15-8 Graphite Machining Tips 15-8 Suppliers of EDM Graphite 15-9 X Chapter 16 Flushing 16-1 EDM Flush Fittings 16-1 Jet Flushing 16-2 Through-electrode Pressure Flushing 16-2 Sealed Flush 16-3 Pot Flushing 16-3 Suction Flushing 16-4 Trepanning 16-4 Chapter 17 Your First Burn 17-1 Chapter 18 Jewelry Manufacturing and EDM Tips 18-1 Using Tokens and Coins as an Electrode 18-1 Using a Copper Earring as an Electrode 18-2 Pressed Arbor 18-3 Glued Arbor 18-3 Glued-together Electrodes 18-3 Upside Down and Sideways 18-3 Carbide Insert Tool Holder 18-3 Multiple Electrode Burns 18-4 Broken Screw and Bolt Removal Techniques 18-4 Chapter 19 Glossary 19-1 Chapter 20 Reference Materials 20-1 Parts List 21-1 Electronic 21-1 Non-Electronic 21-3