The Process of Spark Erosion and Its Advantages
23 August 2022
Manufacturing companies have been maximising a wide array of processes to ensure that they can generate the needed parts and products for their clients and customers. One of the processes they often utilise is machining.
Machining is a process wherein some parts of a workpiece are cut and removed to generate the final shape and size. Different tools are maximised in conducting this process. Some of these tools include lathes, drilling machines, milling machines, and power saws. Most of these tools are used to carry out various machining processes like turning, milling, and drilling.
But for modern machining processes like spark erosion, more complex tools are used to carry out the said process.
An Overview of Spark Erosion
Spark erosion, also known as electrical discharge machining or EDM, is a machining process wherein specific materials are removed from the workpiece using current or electrical discharges. These discharges, which can also be characterised as sparks, come from two electrodes normally separated by a dielectric liquid. This specific liquid serves as a conductor and a cooling agent when conducting the spark erosion process.
The Process of Spark Erosion
The two electrodes used to generate sparks are comprised of the tool-electrode and the workpiece-electrode. To make the spark erosion successful, the workpiece and the tool must not make any physical contact. Only the sparks generated by the electrodes are allowed to make contact with the workpiece, removing some materials to achieve its required dimensions.
The electrodes are then separated by a dielectric liquid. This liquid breaks down as the voltage increases and the strength of the electricity between the electrodes expands. Afterwards, an electric arc will be left in its place, allowing the material to be removed from the electrodes.
A new dielectric liquid will then be formed once the current has stopped, which results in the thermal shock of the metal and the generation of hot plasma on the workpiece, moulding it into a shape in opposition to that of the electrode.
Advantages of Spark Erosion
Tons of advantages are associated with spark erosion.
For one, spark erosion is well-known for its versatility. Different businesses would want to acquire workpieces with varying shapes and specifications. Fortunately, spark erosion is highly capable of cutting simple to complex workpieces without any issues. Another great advantage of spark erosion is it minimises damage. Since the electrode and the workpiece do not interact directly, manufacturers can expect their products to be free from damage.
Spark erosion is also advantageous for manufacturers and industries as it can generate products with a good surface finish. The whole process is likewise cost-effective since setup and breakdown are straightforward. It can even be managed by one person. The upkeep requirements of spark erosion are also minimised significantly.
Spark Erosion Key Applications
The process of spark erosion can be maximised in industries such as gas, oil, aerospace, and even nuclear. Most of these industries use spark erosion in recovering machines that have been damaged or compromised by broken tools.
To know more about spark erosion, you can contact us at Amon Engineering.
References:
https://www.amedm.co.uk/spark-erosion-explained
https://electroarc.com/what-is-the-spark-erosion-process
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