Abstract: An EDM wire having an outer coating of epsilon phase brass and a process for manufacturing the EDM wire is provided. The process includes coating a copper bearing metallic core with zinc. The zinc coating is then converted to epsilon phase brass by heat treating the wire at a temperature low enough to minimize or eliminate any resulting changes in the mechanical properties of the wire. The coated core wire may be drawn to a finish size prior to heat treatment which will result in a wire with a substantially continuous epsilon phase coating.

Abstract: Disclosed are various embodiments of an EDM electrode dressing template comprising a body made of an electrically conductive material. Bonded to the body is a pad with an electrically conductive material with hardness greater than the body. An electrode with an eroded end is positioned proximate the pad and a DC current pulses between the eroded end and the pad. After a period of time, the eroded end is shaped into a dressed tip. Since the pad is less susceptible to spark erosion than the body, the electrode is more consistently dressed and the template is replaced less frequently.

Abstract: An electrical discharge machining assembly has a fixture that retains an electrode. The fixture has clamps to apply a clamping force to the electrode. A threaded member adjusts the compression of a spring to change the clamping force for each clamp. For each clamp, the spring applies a force to a clamp lever pivotably attached to the fixture. Pivoting of the clamp lever moves a lower portion of each clamp lever closer to the fixture clamping the electrode to the fixture body. A clamp release is located proximate to the fixture to rotate the clamp levers in an opposite direction releasing the clamping pressure and the electrode.

Abstract: An electrical discharge machine for improving the guide alignment base structure consisting of a guide alignment base having vertical threaded holes. Furthermore, the guide alignment base has axial adjustment holes that are respectively aligned with the vertical threaded holes, the diameters of the axial adjustment holes slightly larger than the diameters of the vertical threaded holes to enable the insertion of adjustment screws through the axial adjustment holes and fastening into the vertical threaded holes. With a spherical body in between serving as a center, the adjustment screws tilt the guide alignment base forward, backward, leftward, and rightward to adjust the perpendicularity of the guide. Horizontal adjustment screws through the guide alignment base secure the guide alignment base transversely such that the guide alignment base effectively achieves stable positioning to thereby prevent the vertical and horizontal deviation of the guide alignment base when it is impacted.

Abstract: An electrical discharge machine is configured to (i) machine at least a portion of a workpiece through electrical discharge between the workpiece and a first machining electrode aligned by the electrode guide; (ii) generate a dressed machining electrode by engaging a machining electrode aligned by the electrode guide with the electrode dresser; and (iii) machine at least a portion of a workpiece through electrical discharge between the workpiece and the dressed machining electrode. Additional electrical discharge machines and methods of machining are provided.

Abstract: A low cost electrical discharge texturing machine which can texture work rolls having a broad range of diameters and lengths either on a production or research and development basis. The machine is relatively portable, for example, it can be mounted on a palate, and can be used at any location having an adequate electrical supply. Electrodes are mounted on the machine in a manner which maximizes flexibility in respect of the roll diameters that can be textured. The machine also has adjustable supports for the work rolls which can raise or lower a roll surface relative to the electrodes to provide additional flexibility in the roll dimensions that can be textured. Furthermore, the machine has programmable x-axis drives and these can optionally be used in combination with programmable roll drives.

Abstract: An EDM electrode curved in both the the Z and the Y planes permits the formation of film cooling holes in a highly contoured article.

Abstract: An electrical discharge machine includes first and second coaxial electrodes and corresponding carriages. A liquid dielectric is channeled between the electrodes and a workpiece which are suitably electrically powered for machining a duplex hole in the workpiece.

Abstract: A small hole electric discharge machining equipment automatic electrode change device having an electrode docking turntable having a plurality of mounting slots located at equal intervals, each with a magnet, holding an electrode chuck. When changing a used electrode chuck on the quick-release collet is required, a first cylinder moves the electrode docking turntable forward and the mounting slot receives the used electrode chuck, which is attracted to one magnet. The quick-release collet then releases the used electrode chuck. The machining rotatory spindle automatically rises and the electrode docking turntable returns to an original position. The electrode docking turntable rotates and positions a new electrode chuck below the quick-release collet. The electrode machining rotatory spindle then lowers attaching the electrode chuck to the quick-release collet, following which the electrode docking turntable returns to the original position, removing the electrode chuck from the mounting slot.

Abstract: A method and apparatus for electric-discharge machining a turbine blade are provided. The method includes the steps of: a) preparing a disc material divided into an first portion and a second portion on a basis of a symmetrical line, b) fixing the disc material, with the first portion facing upward, c) forming an initial profile of at least one of the plurality of blades at the first portion of the disc material using at least two roughing tool electrodes to concurrently form a roughing space at the first portion, d) leading at least two finishing tool electrodes into the roughing space to concurrently perform precise machining of the blade, e) turning over the disc material, fixing the disc material and repeating steps c) and d) on the second portion.

Abstract: A system and method for determining the approximate weight of metal consumables used by an electric arc welder over a period of welding time, the system comprises a program to calculate the total energy exerted by the welder over a period of welding, a divider to divide the total energy by a number including a power of a selected non-unity factor to obtain said weight. When the energy is in mega joules the factor is in the range of 3.2–4.2 and preferably approximately 4.0.

Abstract: A method and device for monitoring the condition of an electrode in an electro-discharge machine are disclosed. The device includes an electrode detector operable to produce a position signal indicative of the position of an end region of the electrode in the nose-guide, and a signal processing unit connected to receive a position signal from the electrode detector and operable to determine from the position signal when retraction of the electrode into the nose-guide has occurred. The method monitors the position of the end region of the electrode and determines when retraction of the electrode has occurred.

Abstract: An EDM drill comprised of an automated electrode tube replacing means to allow fully automated and continuous working on holes; and further comprised of an electrode tube guide selection device to allow fully automated and continuous working on holes of various diameters.

Abstract: An electrode guide and a method for the spark-erosion of workpieces are disclosed. The electrode guide (1), consisting of a two-piece prism-shaped (2, 3) guide with a pretensioning device (6), enables an electrode (4) to be guided in a play-free manner, thus allowing the production of bores that is accurate to within 1 ?m. A pivoting device (10) for pivoting the electrode guide and an alignment device (14) for the parallel displacement of the electrode guide (1) are also provided, enabling the production of conical bores.

Abstract: A tool attachable to a spindle of a machine tool by an automatic tool changer in the same way as an ordinary tool, capable of being driven without connecting with an external power supply etc., and able to rotate at a rotational speed different from than that of the spindle of the machine tool without supply of electric power from the outside, provided with a machining tool for machining a workpiece, a motor connected with the machining tool and rotating the machining tool, and a generator to which rotary force is transmitted from the spindle of the machine tool and generating electric power to drive the motor, the shaft of the motor being arranged in an orientation different from the axial center of the spindle.

Abstract: An electrode holder for EDM machines using automatic tool changing techniques provides a base plate that may be attached to an adapter of third party chuck systems and a simple compressed slot mechanism for holding the electrode without the need for epoxy or the like.

Abstract: A carbon nanotube apparatus for surface discharge polishing using a transistor discharge circuit includes a signal generator having a integrated circuit for generating square wave; a photo coupler for isolating a cathode of the apparatus and an anode for processing; a discharge machining area comprising the anode for placing a target and the cathode having more than one multi-wall carbon nanotubes (MWCNT) grown on it. The apparatus uses the signal generator to control a waveform of square wave for electrical discharge machining and to control a current value for nanotube tips for electrical discharge machining, thus to enable the cathode of MWCNT apparatus for nanometer-level micro machining.

Abstract: A miniature machine tool for micro-machining is capable of performing on a workpiece at least one conventional mechanical machining operation and another micro-machining operation such as electrochemical machining (ECM), electro deposit machining (EDM), micro-milling or micro-turning or micro-drilling. The machine tool includes a holder in which the workpiece is clamped during all successive machining operations so that the machining operations may be performed in succession without intervening reclamping of the workpiece. This increases dimensional accuracy when micro-machining high-precision components.

Abstract: Powder of a simple substance or a combination of a plurality of carbides of metals belonging to the IVa, Va and Via families in the Periodic Table is mixed with a ferrous-family metal powder or non-ferrous metal powder having the same composition as the treatment target (2) as a simple substance or a combination of a plurality of metals, and this is compressed and molded, and incompletely sintered to form an electrode (12) serving as a discharge processing electrode; and said device is provided with a switching unit which alters electrical conditions at the time when the base member of the treatment target (2) is directly subjected to a discharging surface treatment and the electrical conditions at the time when a coating film (13) that has been formed is subjected to a discharging surface treatment according to the characteristics of the treatment target material.

Abstract: An EDM drill is provided which includes an automated electrode tube replacing mechanism for fully automated and continuous operation. The EDM drill further includes an electrode tube guide selection device to allow the fully automated and continuous operation on holes of various diameters.

Abstract: A guide bushing for use in association with electrical discharge machining (EDM) apparatus including a rotatable electrode defining a longitudinal axis, is provided. The guide bushing includes a body portion defining a bore therethrough for receiving at least a portion of the electrode therein. The bore includes a proximal portion sized to be in contact with an outer surface of the electrode, an intermediate portion sized to be spaced from the electrode, and a distal portion sized to be at least partially in contact with the outer surface of the electrode.

Abstract: A method for forming non-separating diffusers in a part includes fabricating at least one metering hole in a part, and fabricating at least one diffuser hole with an electrode comb in the part such that the diffuser hole intersects the metering hole at a transition region. The electrode comb includes a tooth including a nose comprised of a plurality of diffuser surfaces intersecting at a point on a tooth centerline. Each diffuser surface has a diffuser angle, and at least one of the diffuser surfaces is truncated by an offset from the tooth centerline.

Abstract: Manufacturing narrow-diameter hollow metal objects utilizing metals difficult to work plastically has been problematic with conventional manufacturing methods; the narrower the diameter the higher the manufacturing cost has been, and under some circumstances manufacturing has been impossible. A plurality of metal wires is worked into a twisted wire cluster, adjoining companion metal wires are brought into contact in planar contacting portions, and the cluster is made unitary by supplying an adhesive agent along the outer side, producing a hollow metal object possessing a uniform inner diameter and a clean inner surface.

Abstract: Automated wire connection is performed, and when the wire connection succeeds, the wire feed rate during the next connection is set to a value one stage faster. On the other hand, when connection fails the wire feed rate is set to a value one stage slower.

Abstract: A hole-drilling guide for directing a flexible hole-drilling instrument includes; a body made of an electrically insulating material, at least one inlet aperture penetrating a face of the body, at least one exit aperture penetrating a face of the body and a hollow, nonlinear raceway linking the inlet and exit apertures.

Abstract: An EDM drill comprised of an automated electrode tube replacing means to allow fully automated and continuous working on holes; and further comprised of an electrode tube guide selection device to allow fully automated and continuous working on holes of various diameters.

Abstract: A discharge electrode comprising a material having solid lubricant effect, such as molybdenum, is used to generate discharge in a pulse form between the discharge electrode and a workpiece, the surface of which is to be treated, in working liquid containing carbon components, such as water. Material consumed or melted from the discharge electrode, generated because of the electric discharge energy based on the pulse form discharge, gets adhered to and deposited onto a surface of the workpiece thereby forming a coat having lubricant effect on the surface of the workpiece.

Abstract: An electrode holder for EDM machines using automatic tool changing techniques provides a base plate that may be attached to an adapter of third party chuck systems and a simple compressed slot mechanism for holding the electrode without the need for epoxy or the like.

Abstract: WC powder (11) and W powder (12) are mixed and entered in a press mold and compressed and molded, thereby forming a discharge surface treatment electrode (10). Discharge is caused to occur between the discharge surface treatment electrode (10) and a workpiece (16) by a discharge surface treatment power unit (17), whereby a component of the discharge surface treatment electrode (10) melted by discharge heat is deposited on the workpiece (16). W, a component of the discharge surface treatment electrode (10), reacts with C, a component of work liquid (4), to produce WC and together with the WC which is a component of the discharge surface treatment electrode (10) a hard film (20) made of WC is formed on the workpiece (16). The hardness and strength of the hard film formed on the workpiece (16) by the discharge surface treatment can be enhanced.

Abstract: In a micro electro discharge machining method and apparatus, the shapes of minute holes are transferred to a tool electrode through a plate electrode serving as an intermediate electrode, and a workpiece is machined using the tool electrode. As a result, the time for machining is reduced. During the electro discharge machining process, the relative distance between the tool electrode and the plate electrode or the workpiece is changed at a prescribed frequency and discharge pulse output is controlled in synchronization with the change in the relative distance between the tool electrode and the plate electrode or the workpiece, so that high precision machining is enabled.

Abstract: Complex features and fine details in a Carbon—Carbon work piece, for example, are formed by electrical discharge machining (EDM). An electrode used in the EDM is made of a material that is mechanically and chemically compatible with Carbon—Carbon composite material.

Abstract: Method and arrangement for manufacturing a disk-shaped or annular stator component or rotor component with a plurality of blades arranged one after another in a path extending around the component and a cover (15) arranged outside the blades in the radial direction and in contact therewith. According to the method, at least a portion (11) of a first set of channels (12) is spark-eroded simultaneously out of a disk-shaped or annular workpiece (2) intended for forming the component at a distance from the edge (14) of the workpiece in the radial direction, which channels (12) are intended to delimit the blades in the circumferential direction of the workpiece.

Abstract: An electric discharge machining electrode adapted to improve the quality of a finished surface of an article by increasing a machining speed by improving the electric discharge generation rate &eegr; even in a fine machining process; and by rendering it possible to maintain constant the electric discharge generation rate &eegr; even when a time width and a voltage of the electric discharge pulses are reduced. In an electrode used in the electric discharge machining process carried out by generating electric discharge pulses between the electrode and an article, a radioactive metal is contained in the portion of the electrode in which the electric discharge pulses occur, or in the portion thereof which is in the vicinity of the portion in which the electric discharge pulses occur.

Abstract: A green-compact electrode (1) for discharge surface treatment for use in a discharge surface treatment operation for forming a hard coating film (9) on the surface of an object (2) which must be machined by performing a discharging operation in working fluid (4) is structured such that powder (11) made of metal, such as W or Ti, and fluid (12) which is the same as working fluid are mixed with each other, and the mixed substance is compression-molded so that the green-compact electrode (1) for the discharge surface treatment is obtained.

Abstract: An electrode holding and dispensing assembly for use with an electrical discharge machining apparatus. The assembly includes a guide rail having a channel formed therein and an electrode dispenser positioned to deliver electrodes to the channel. A slider is slidingly received in the channel for advancing electrodes delivered to the channel from the dispenser to an electrode seating site located in the channel, where the electrode is securely held during machining operations.

Abstract: A ring or inverted-cup shaped cutting element is used as a tool electrode for electromachining to rough machine the airfoils on blisks to near net shape. The cutting element is rotated and positioned with respect to the blisk by a CNC (Computer Numerically Controlled) drive arrangement.

Abstract: A tool attachable to a spindle of a machine tool by an automatic tool changer in the same way as an ordinary tool, capable of being driven without connecting with an external power supply etc., and able to rotate at a rotational speed different from than that of the spindle of the machine tool without supply of electric power from the outside, provided with a machining tool for machining a workpiece, a motor connected with the machining tool and rotating the machining tool, and a generator to which rotary force is transmitted from the spindle of the machine tool and generating electric power to drive the motor, the shaft of the motor being arranged in an orientation different from the axial center of the spindle.

Abstract: An electrical discharge machine for forming a small hole including an intermediate guide having an upper guide and lower guide to support an electrode for forming a small hole at two points between an electrode holder and a small hole guide and also having a chuck, which can be opened and closed, provided in each guide; a first drive unit to drive the intermediate guide in the longitudinal direction of the electrode, a second drive unit to open and close the guide chucks of the intermediate guide; and a third drive unit to variably change distance L between the upper guide and lower guide of the intermediate guide in the longitudinal direction of the electrode.

Abstract: An electric discharge machining electrode adapted to improve the quality of a finished surface of an article by increasing a machining speed by improving the electric discharge generation rate &eegr; even in a fine machining process; and by rendering it possible to maintain constant the electric discharge generation rate &eegr; even when a time width and a voltage of the electric discharge pulses are reduced. In an electrode used in the electric discharge machining process carried out by generating electric discharge pulses between the electrode and an article, a radioactive metal is contained in the portion of the electrode in which the electric discharge pulses occur, or in the portion thereof which is in the vicinity of the portion in which the electric discharge pulses occur.

Abstract: A wire electrode for spark erosion cutting of metals, electrically-conducting ceramics etc., comprising either a homogenous centre (1) made of a metal or of a metal alloy, or a composite centre made from a steel core with a coating of copper or copper alloy, wherein the wire electrode comprises at least two sheath coatings made of zinc alloys, with said coatings wearing during erosion. In order to increase performance during high-speed cutting, such a wire electrode comprises an inner sheath coating (2) predominantly comprising &bgr;-brass, and an outer sheath coating (3) predominantly comprising &ggr;-brass, wherein the fraction of &bgr;/&bgr;′-phase or &ggr;-phase in the two sheath coatings is at least 60%. The ratio of the coating thickness of &bgr;-brass to &ggr;-brass is between 0.3 and 7. The sum of the thicknesses of both sheath coatings in relation to the external diameter of the electrode is between 0.1 and 0.3.

Abstract: A tube electrode stabilizer for an EDM drilling includes a stabilizer block and a mover. The stabilizer block has a concaved in shaped supporting wall that parallels to the traveling path of a tube electrode, and has a plurality of apertures interconnected to air vacuuming connections to suck air. The mover is connected to the stabilizer block for approaching the tube electrode. Suction force pushes the tube electrode against the supporting wall to achieve stabilization of the tube electrode. The stabilizer block further has a sensor to detect whether the tube electrode is seated into the stabilizer block or not and to measure the available length of the tube electrode before or after drilling.

Abstract: A device for electrical discharge machining at least one rectilinear cooling air passage having a flared opening in the wall of a hollow turbine vane. The device includes at least one forming electrode attached to a first electrode holder and includes a first face provided with a groove for guiding a rectilinear electrode configured to drill the rectilinear part of the air passage, a median portion with a constant section, and a pointed end portion with a section that decreases between the median portion and the point of the forming electrode.

Abstract: The invention relates to a device for the electrical discharge machining of at least one rectilinear cooling air passage (6) having a flared opening (8) in the wall of a hollow turbine vane (2). The inventive device comprises at least one forming electrode (10) attached to a first electrode holder and intended to produce the flared outlet opening. The forming electrode (10) comprises a first face(28a) which is provided with a groove for guiding a rectilinear electrode (7) designed to drill the rectilinear part of the air passage (6), a median portion (28) with a constant section and a pointed end portion with a section that decreases between the median portion and the point of the forming electrode.

Abstract: The present invention involves a process for increasing coolant side surface roughness on castings such as airfoils, shrouds, nozzles or the like by electrical discharge machining (EDM). An EDM electrode is shaped to fill completely or a portion of a cavity in the casting, the electrode is then connected to an electric discharge machine, and the internal surfaces of the internal core cavity are then machined to form a roughened surface.

Abstract: Electrical discharge machines are disclosed that are capable of a relatively wide range of flexibility and range of motion for performing electrical discharge operations. The electrical discharge machine herein can optionally comprise up to, and in excess of six axes of motion to adjust the electrode relative to the workpiece. To effectively remove the swarf that is generated during electroerosion operations, a primary flushing system and an optional auxiliary flushing system are provided. The auxiliary flushing system is used to direct dielectric fluid towards the workpiece external to the electrode. Further, methods of performing high speed electrical discharge machining operations are disclosed, including methods for establishing the zero set conditions that indicate initiation of the electroerosion process based upon a detection of dither on the electrode travel.

Abstract: An electrode guide and a method for the spark-erosion of workpieces are disclosed. The electrode guide (1), consisting of a two-piece prism-shaped (2, 3) guide with a pretensioning device (6), enables an electrode (4) to be guided in a play-free manner, thus allowing the production of bores that is accurate to within 1 &mgr;m. A pivoting device (10) for pivoting the electrode guide and an alignment device (14) for the parallel displacement of the electrode guide (1) are also provided, enabling the production of conical bores.

Abstract: A sealing apparatus for effecting a temporary seal against an elongate object. The object is placed in a chamber(17) and supported between inlet and outlet apertures in the walls of the chamber. A resilient seal (32) is placed at the point where the object passes through one of the apertures. A piston (34) is located on the remote side of the seal being operable to compress the seal towards the relevant aperture thereby deforming the seal laterally into contact with the object to seal the periphery of the object. When the piston is released, the seal reverts to its relaxed condition thereby enabling the object to be moved between the two apertures.

Abstract: A tool holder for an electric discharge machine has a top base, a securing collar, a positioning sleeve. an adjusting base and a rotating base. The top base has a central hole and an elongated opening communicating with the central hole. The securing collar is screwed into the central hole in the top base and has a central hole with a conical inner surface. The securing collar has multiple holes corresponding to the elongated opening in the top base. A positioning sleeve has a conical outer surface fitting with the conical inner surface in the securing collar. The adjusting base has a main shaft penetrating through the central hole in the positioning sleeve. Consequently, the locked condition of the main shaft is released by rotating the securing collar, such that the adjustment of the tool holder is convenient.

Abstract: A perforated electrode has strategically distributed flushing holes through which a flushing medium is discharged. The electrode can be used for either electrochemical machining (ECM) or electrodischarge machining (EDM). The flushing medium is either electrolyte in ECM or a dielectric fluid in EDM. It is discharged from the tool electrode directly against the workpiece surface or surfaces which are undergoing material removal. This removes heat and sludge or debris.

Abstract: A holder for a workpiece or tool, in the surface of which a plurality of grooves with substantially planar flanks are made, the opposing edges of which, formed on the surface, have a predetermined spacing, wherein the holder consists of a sintered material, at least in the region of the elastically deformable edges.