9 replies to this topic

[danielm]

The mat'l is some 9000 series hardened steel at 55hrc...a sector gear.  An EDM vendor quoted a per part time of 28 minutes.  I'd like to do something like plunge rough with a ceramic insert but the root diameter is pretty small...about .177dia.  I uploaded the MCX-6 file here: ftp://mastercam-cadcam.com/Mastercam_forum/X6_FIles/EDM SAYS 28MINUTES.MCX-6

Maybe a 2D dynamic toolpath???? But man...I don't think that I can beat 28minutes.  I know that its going to spring some to so I'd have to stop to re-clamp.

I've seen ceramic inserts to some pretty amazing stuff in inconel.  If I could crank up the R's and plunge with some kind of .250dia ceramic cutter at a crazy feed rate of 40-60ipm, then 2D HFM the rest.....

Any suggestions?  Heres what the part looks like with the stock drawn around it:

[Joe788]

How thick is that stock? Can an EDM really cut that in 28 minutes? I've never used a wire EDM, but I thought feedrates were typically more like inches per hour than 2+ inches per minute.

[GoetzInd]

+1 to Joe. My wire experience is limited, but I doubt 28min is possible. However, milling that in 28min at 55hrc is a tall order. I guess it depends on your definition of "rough".

Mike

[Guyinthedesert]

Joe788, on 11 August 2012 - 12:47 PM, said:

How thick is that stock? Can an EDM really cut that in 28 minutes? I've never used a wire EDM, but I thought feedrates were typically more like inches per hour than 2+ inches per minute.

Keep in mind that the wire EDM is going to stack the parts up, so the real cycle time might be more like 4hr to do 8 pcs.

We've had great luck cutting starter gear teeth in flywheels over 70Rc using AlCrona coated endmills, using straight oil.

[Redfire427]

That's a wire-cutting job no matter how you look at it. Even if they do stack 8 pieces together ( unsure of thickness ), 28 minutes is a bargain. Based on the perimeter of the part, that wire edm would have to be flying.

Carmen

[JAMMAN]

I'm with Carmen on this one, I had a good friend for about 4 years owned a WEDM shop, all Mits. Wire is the only way to do that with any speed and accuracy at all. Cut around the entire thing.

28 minutes is a bargain, depending on the thickness.

[Guyinthedesert]

Also, make sure your customer will allow EDM. None of ours will, unless we machine off the recast layer

[Oppiz]

Redfire427, on 11 August 2012 - 04:54 PM, said:

That's a wire-cutting job no matter how you look at it. Even if they do stack 8 pieces together ( unsure of thickness ), 28 minutes is a bargain. Based on the perimeter of the part, that wire edm would have to be flying.

Carmen

You got that right. I've been running wire EDM's for 20 years, the only way you can cut one of these in that time would stacking them and only 1 pass. So if a good finish is needed it might be a little rough(as far as EDM finishes go).  Also you might get a slight variation in parts do to the wire bellying in one pass. it all depends on thickness.

[Del.]

Better jump all over the 28 minutes quote. I wouldn't do it for that if it was only an 1/8''thick.

[Tyler Robertson]

high pressure waterjet going deadly slow with 28 heads