Mirror EDM (Electrical Discharge Machining), or mirror electrical discharge machining, is mainly applied to the precision machining of complex mold cavities, especially complex curved surfaces that are inconvenient for polishing operations. It can eliminate the manual polishing process, improve the service performance of parts, and is of great practical significance for shortening the mold manufacturing cycle.
Functions of Mirror EDM machines
Mirror electrical discharge machining is mainly used for the precision machining of complex mold cavities, especially complex curved surfaces where polishing is difficult to perform. It can omit the manual polishing procedure, enhance the service performance of components, and plays a crucial practical role in reducing the mold manufacturing cycle.
Development of Mirror EDM machines
After conductive micro-powders enter the discharge gap, they are equivalent to connecting multiple segments of small conductors between the two electrodes. At the same time, they also cause distortion of the electric field in the discharge gap, which reduces the breakdown resistance of the insulating medium in the gap, making discharge easier to occur and the discharge gap increase accordingly. The expanded discharge gap reduces the triggering effect of electrolytic products on discharge and facilitates the flow and discharge of electrolytic products, thereby reducing the occurrence of concentrated discharge and enabling uniform distribution of discharge on the machining surface.
With the increase of the discharge gap, the discharge channel becomes thicker. Under the same discharge pulse energy, the heated area on the workpiece surface increases while the heating intensity decreases, resulting in the formation of large and shallow discharge craters on the workpiece surface. Meanwhile, the increase of the discharge gap also reduces the throwing capacity of the discharge on the molten metal, allowing more molten metal to re-solidify on the workpiece surface and further reducing the depth of the discharge craters. Therefore, powder-mixed electrical discharge machining forms large and shallow discharge craters on the workpiece surface.
The formation of large and shallow discharge craters and their uniform distribution on the workpiece surface through powder-mixed electrical discharge machining are the fundamental reasons for reducing the machining surface roughness.
Performance Characteristics of Mirror EDM Machines
Outstanding EDM control system: Standard configuration with 3-axis 3-linkage (4-axis 4-linkage or 5-axis 5-linkage can be realized by optional domestic configurations).
The discharge system has a built-in ultra-precision machining circuit (PIKA mirror machining function).
Equipped with automatic machining function (AUTO function), automatic positioning function, automatic arc-clearing circuit, liquid temperature and liquid level control, automatic fire-extinguishing device, power-off recovery function, etc.
Rich process database, covering more than ten types of material pairs.
Touch screen and multi-functional manual control box for user-friendly operation.
High precision: It realizes high precision of machine tool machining (repeat positioning accuracy ≤ 2μm), high efficiency (≥ 500mm/min), optimal surface finish (Ra ≤ 0.1μm), low electrode wear rate (≤ 0.1%), tool lifting and servo discharge machining in any axial direction, complex 4-axis 4-linkage machining, and expert process database machining suitable for various materials. It is a product with high performance and cost-effectiveness.
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