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 electrical discharge machining head incorporating piezo-electric motors for controlling motion of a slide assembly. The slide assembly is translatable within a machine base and its motion is controlled by the piezo-electric motors. The slide assembly precisely controls the movement of an EDM electrode through the wire guide.

Abstract: Apparatus and method for erosion machining a structure comprising one of a metallic structural component, a metallic insert element, and a connecting element, by way of erosion. The apparatus includes an eroding head including an electrode, a power supply, and a control device. The power supply and the control device produce an erosion current. A grounding device is arranged in an area of the eroding head and includes at least one contact element. When the eroding head is arranged to perform erosion machining, the at least one contact element contacts and forms an electrical connection with a surface of the structure, whereby an eroding electric circuit is formed via the electrode and the structure.

Abstract: Spark erosion system for removing connection elements from a structure (W, 60), having a drill head (3) [(4)?], a rotational drive (10) by means of which a tool is caused to rotate, a positioning system (15) for moving the tool as well as a process control (48) for controlling the overall system, the system comprising an energy unit (30) and an electric circuit, and in that, furthermore, the tool is a tube electrode (5) through whose interior (5a) a dielectric can be guided to the surface (61a) of the connection element (61) to be detached, which surface (61a) faces the interior (7a), in order to cause a voltage between the tube electrode (5) and the connection element (61) to be detached, for implementing a spark erosion.

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: A machining apparatus is provided. The machining apparatus includes a discharge machining head assembly and a slide assembly supporting the head assembly. The machining apparatus also includes an electromagnet configured to support the slide assembly in a position on a work piece to machine an area. The slide assembly permits linear displacement of the head assembly generally parallel to the supporting work piece surface.

Abstract: A small hole electrical discharge machining apparatus includes an electrode holder that holds an upper part of an electrode, an electrode guider that guides a lower part of the electrode, a jet nozzle that injects water jet to the electrode holder, and a fluid channel that supplies a gas, such as air, to an electrode guide of the electrode guider. The electrode is guided with the water jet toward the workpiece, such that small hole electrical discharge machining is performed while the gas is being released from the electrode guide into a working liquid via the fluid channel.

Abstract: An electric discharge machining apparatus has improved responsive drivability and improved machining speed. A tool electrode has a tip end directed toward a work piece, a voltage applied between the tool electrode and the work piece generating a discharge. A drive shaft is connected with the tool electrode. An electrode driving device has magnetic bearings for moving the drive shaft in three directions, including a Z-axis direction, which is an axial direction of the drive shaft, a Y-axis direction perpendicularly crossing the Z-axis direction, and an X-axis direction perpendicularly crossing the Y-axis direction and Z-axis direction, by supplying electric current to electromagnetic portions to control magnetic attraction. A movable coupling is connected with an end of the drive shaft and is movable in the three directions. An electric motor is connected with an end of the coupling for rotating the drive shaft through the coupling.

Abstract: A small-hole electrical discharge machining device comprises a diaphragm which can be moved up and down along a notch window provided in a work tank for mounting a work in the work tank in which a working fluid can be filled or discharged, and adjusts the height of the working fluid; a W-axis slide which can be moved up and down, and having an electrode guide in the lower end portion; a master cylinder which is moved up and down corresponding to up-and-down movement of the W-axis slide; and a slave cylinder which is connected with the master cylinder through a pipeline and with a diaphragm driving mechanism, and wherein the diaphragm is moved up and down corresponding to up and down movement of the W-axis slide.

Abstract: An electrical discharge machining apparatus is provided with at least two work stations. A first servomotor is mounted above the first and second work stations, and a second servomotor mounted to the first servomotor so as to be selectively positioned over either of the first and second work stations by the first servomotor. The second servomotor is capable of causing relative motion between an electrode and a workpiece fixture in the first work station when positioned over the first work station and causing relative motion between an electrode and a workpiece fixture in the second work station when positioned over the second work station.

Abstract: An electrical discharge machining (EDM) apparatus includes a plurality of machining heads, at least one EDM control system, and a plurality of programmable servo drives. Each one of the programmable servo drives is connected to the EDM control system and to a respective one of the plurality of machining heads. The programmable servo drives receive a velocity command from the EDM control system and feed a control signal to a respective one of the plurality of machining heads to control electrode positioning.

Abstract: Spark erosion system for removing connection elements from a structure (W, 60), having a drill head (3) [(4)?], a rotational drive (10) by means of which a tool is caused to rotate, a positioning system (15) for moving the tool as well as a process control (48) for controlling the overall system, the system comprising an energy unit (30) and an electric circuit, and in that, furthermore, the tool is a tube electrode (5) through whose interior (5a) a dielectric can be guided to the surface (61a) of the connection element (61) to be detached, which surface (61a) faces the interior (7a), in order to cause a voltage between the tube electrode (5) and the connection element (61) to be detached, for implementing a spark erosion.

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: 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: An electric discharge machining sampling apparatus for obtaining samples from a surface of metal components provided. In an exemplary embodiment, the sampling apparatus is operable underwater and includes a base plate and an electrode assembly movably coupled to the base plate. The electrode assembly includes an electric discharge electrode and an electrode holder with the electrode including at least one bore extending therethrough. The sampling apparatus also includes a particle collection assembly operatively coupled to the electrode. Each electrode bore is in flow communication with the particle collection assembly.

Abstract: A small hole electric discharge machine drill is provided with a depth-specific processor and a tiltable unit operable in fluid. The turntable unit includes a first axis with a first center of rotation and a second tilting axis with a second center of rotation. The turntable unit is provided inside a work tank that may be filled with fluid. The small hole electric discharge machine drill includes an electrode for small hole processing.

Abstract: The present invention provides an electrical discharge machine (EDM) with double-axis double-speed linear motor mechanism for fast machining operation. In this EDM the tool fixture assembly is driven by a linear motor, whiles the work piece platform assembly is driven by another linear motor in the opposite direction. Applying no contact direct drive, such as linear motors, eliminates wear problem in ballscrews in conventional embodiments and enhances availability of the machine. Opposite and double motors drive configuration not only increases relative speed between the tool electrode and the work piece, but also stabilize the speedy jump operation by canceling reaction force of tool electrode movement.

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: 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 EDM apparatus for reducing wheel runout includes a support structure. The support structure is adapted to support and rotate a vehicle wheel. An electrode is also included for electric discharge machining at least one surface of the vehicle wheel.

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: 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 apparatus for electrode charge machining includes a T-shaped quill movable in the vertical direction, at least two linear motor yokes attached to the quill symmetrical about the fixed point of the piston rod of a counter balance device and moving in parallel, at least two linear motor permanent magnets facing the yokes, an electrode mounting device fixed at the lower end of the quill, the counter balance device for balancing a gravitational force acting on the quill and the tool electrode. The gravity balance device consists of an air cylinder with the piston rod. And the air cylinder is fixed with a support frame, with the piston rod extending down into the quill and fixed with a level plate in the quill in the coaxially with the quill.

Abstract: An electrical discharge machining system for machining a workpiece. The system comprises a wire guide support for positioning and guiding a wire electrode into a desired position relative to the workpiece and a source of a liquid dielectric fluid. The supply also provides means for directing the dielectric fluid from the source to a machining site between the electrode and the workpiece, and for atomizing the dielectric fluid in the machining site.

Abstract: An electrical discharge machining apparatus is provided with at least two work stations. A first servomotor is mounted above the first and second work stations, and a second servomotor mounted to the first servomotor so as to be selectively positioned over either of the first and second work stations by the first servomotor. The second servomotor is capable of causing relative motion between an electrode and a workpiece fixture in the first work station when positioned over the first work station and causing relative motion between an electrode and a workpiece fixture in the second work station when positioned over the second work station.

Abstract: An electrical discharge machining (EDM) apparatus includes a plurality of machining heads, at least one EDM control system, and a plurality of programmable servo drives. Each one of the programmable servo drives is connected to the EDM control system and to a respective one of the plurality of machining heads. The programmable servo drives receive a velocity command from the EDM control system and feed a control signal to a respective one of the plurality of machining heads to control electrode positioning.

Abstract: An electric discharge machining sampling apparatus for obtaining samples from a surface of metal components provided. In an exemplary embodiment, the sampling apparatus is operable underwater and includes a base plate and an electrode assembly movably coupled to the base plate. The electrode assembly includes an electric discharge electrode and an electrode holder with the electrode including at least one bore extending therethrough. The sampling apparatus also includes a particle collection assembly operatively coupled to the electrode. Each electrode bore is in flow communication with the particle collection assembly.

Abstract: In an electric discharge machining apparatus for performing machining while relatively rocking an electrode (18) and a workpiece (W) in a plane vertical to a machining feed direction, there is provided an electric discharge state detection device (20) for detecting an electric discharge state by detecting a short-circuit frequency between the electrode and the workpiece, a defective electric discharge frequency and a position of the electrode, and a rocking function setting device (23) for setting parameters about a rocking function according to the electric discharge state detected by the electric discharge state detection device (20). A parameter setting about a rocking function according to the detected electric discharge state is automatically made without compelling an operator to make the parameter setting about the rocking function, and improvement in machining efficiency and stabilization of the machining can be achieved.

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 small hole electric discharge machine for forming a small hole in a workpiece by generating electric discharge between a rotating elongate pipe electrode (49) having a diameter of 1.0 mm or less and the workpiece. The small hole electric discharge machine may contain a column (11), a W-axis slider (21, 23) attached to the column so as to be moveable in the direction of a vertical W-axis, a Z-axis slider (31) attached to the W-axis slider so as to be moveable in the direction of a vertical Z-axis, a machine head (40) attached to the Z-axis slider the pipe electrode being attached to the machine head, a linear motor (90) for moving the Z-axis slider, and a gas spring (50) for generating a balance force to counteract the gravitational force acting on the Z-axis slider.

Abstract: An electric sparking drill and a method for using the same to drill a hole in a workpiece where at least one of a voltage applied to an electrode, the conductivity of a liquid applied between the electrode and the workpiece during drilling, and a gap between the electrode and the workpiece are controlled to create the desired hole in the workpiece. The electric sparking drill and a method for using the same to drill a hole in a workpiece also improve the hole operation and/or the quality of the hole made by operating at the arcing voltage, including a touch stop function, including a sacrificial electrode, and/or including a guide member function.

Abstract: A combination drilling/tapping electro-discharge machining (EDM) drill capable of selectively operating in hole drilling mode or thread tapping mode is provided. The EDM drill includes a rotation axis as a R axis driven by a servo motor; a machining axis as a Z axis driven by another servo motor being capable of switching between a default mode and a servo following mode for realizing a spark following; and a thread electrode extended down from the R axis through a guide; wherein a dielectric supply and said R axis rotates for performing said EDM thread tapping on a work piece.

Abstract: In an electric discharge machining method and apparatus of dividing a rocking shape for a change in a swing speed and a rocking movement completion determination and determining whether or not a target machining shape is reached every each division shape and completing rocking machining when the rocking movement completion determination is made in all the division shapes, the rocking shape is divided so that either one or both of each corner and the center of each side of the target machining shape is located on a bisector or substantially a bisector of a division angle (&thgr;s).

Abstract: A small hole electrical discharge machining apparatus, including: a slide base; a Z axis slide freely positionable in a vertical direction, the Z axis slide being provided on the slide base; an electrode holding member for holding an upper portion of a stick-shaped or pipe-shaped electrode, the electrode holding member being provided on the Z axis slide so as to be freely rotatable; an electrode guiding member for guiding a lower portion of the electrode, the electrode guiding member being provided on the slide base; and an electrode motor for rotatively driving the electrode holding member, the electrode motor being provided on the Z axis slide. Moreover, the electrode holding member is provided with a jet nozzle for guiding the electrode by use of a water jet.

Abstract: A tool attachable to a machine tool in the same way as an ordinary tool, capable of being driven and operating without connecting with an external power supply etc., and made small enough to enable automatic changing, provided with a generator for generating power by energy of compressed air supplied from the outside, a motor driven by power generated by the generator, and a cutting tool driven by the motor for cutting the workpiece.

Abstract: An electrical discharge machining (EDM) apparatus and method is disclosed that utilizes a rotating electrode for performing the EDM operation to form a desired profile in the work piece surface. A dressing tool located at a side of the rotating electrode opposite from the work piece is operable to dress the surface of the rotating electrode. Operation of the dressing tool is controlled in part by a monitor that monitors changes in the character and condition of the surface of the rotating electrode from certain starting parameters and initiates a dressing operation as needed to restore the starting parameters.

Abstract: An electrical discharge machining (EDM) apparatus includes a plurality of work stations, where each work station has at least one electrode. The EDM apparatus further includes one or more power supplies and a power transfer switch for alternately supplying power to various sets of the electrodes. The power transfer switch has a first state wherein each power supply is connected to a corresponding first electrode in one of the work stations and a second state wherein each power supply is connected to a corresponding second electrode in another work station.

Abstract: An electric discharge machine having an electrode mounting device (42) for mounting a tool electrode, a quill (41) movable in the vertical direction and having the tool mounting device attached to a lower end, at least two linear motor movers (43, 44) attached to the quill and disposed symmetrically about the central axis of the quill, at least two linear motor stators (31, 32), each disposed opposite one of the at least two movers, and a balance device (6) for balancing a gravitational force acting on the quill. The balance device has an air cylinder (60) arranged coaxially with the quill so that a balance force having a force vector aligned with the central axis of the quill is generated. The air cylinder is preferably mounted in a hole formed in the center of the quill and extends in a vertical direction.

Abstract: A method for producing bores in workpieces of electrically conductive material, in particular injection ports (11) in injection nozzles (10) is disclosed, in which method, by means of an erosion wire (12) forming an electrode, material in the workpiece forming the counterelectrode is removed in a targeted way by spark erosion. To produce bores of different cross-sectional shapes and/or a varying cross-sectional area over the length of the hole, the erosion wire (12) is actively excited to a defined vibration, and the form of vibration is established by targeted variation of the vibration excitation in accordance with the desired bore hole shape. A preferred apparatus for performing the method has a fastening unit (13), which receives the end (122) of the erosion wire (12) and which is driven by two actuators (14, 15) to execute a separate oscillating displacement along an x axis and a y axis (FIG. 1).

Abstract: An electrical discharge machining system for machining a workpiece. The system comprises a wire guide support for positioning and guiding a wire electrode into a desired position relative to the workpiece and a source of a liquid dielectric fluid. The supply also provides means for directing the dielectric fluid from the source to a machining site between the electrode and the workpiece, and for atomizing the dielectric fluid in the machining site.

Abstract: A combination drilling/tapping electro-discharge machining (EDM) drill capable of selectively operating in hole drilling mode or thread tapping mode is provided. The EDM drill comprises a rotation axis as a R axis driven by a servo motor; a machining axis as a Z axis driven by another servo motor being capable of switching between a default mode and a servo following mode for realizing a spark following; and a thread electrode extended down from the R axis through a guide; wherein a dielectric supply and said R axis rotates for performing said EDM thread tapping on a work piece. The invention has several configurations.

Abstract: An electrical discharge machining apparatus 10 comprises an electrode assembly 40 having an electrode clamp 54 for clamping a hollow electrode 24. Dielectric fluid is directed through the hollow interior of the electrode 24 to a workpiece 14. A deformable seal 70 seals between the electrode 24 and the assembly 40, and is moveable between a relaxed position (see FIG. 3) in which dielectric fluid can flow between the seal 70 and the assembly 40, and an operative position (see FIG. 5) in which the seal is deformed, and seals between the electrode and the assembly 40. A piston 74 actuates the clamp 54 and also caused deformation of the seal 70. The clamp 54 and seal 70 are capable of receiving an electrode 24 having an external diameter within a 200 micron range.

Abstract: An electrical discharge machining (EDM) apparatus and method is disclosed that utilizes a rotating electrode for performing the EDM operation to form a desired profile in the work piece surface. A dressing tool located at a side of the rotating electrode opposite from the work piece is operable to dress the surface of the rotating electrode. Operation of the dressing tool is controlled in part by a monitor that monitors changes in the character and condition of the surface of the rotating electrode from certain starting parameters and initiates a dressing operation as needed to restore the starting parameters.

Abstract: A method of reducing cutting tool wear in a lubricated metal cutting operation has been developed. An electrical cutting cell is provided having an anodic conductive cutting tool and a cathodic conductive work-piece connected to a DC current supply; the lubricant contains platable wear reducing agents. The lubricant is located to bathe the contacting interface between the cutting tool and work-piece to constitute an electrolyte. Next, the electrical current flow through the contacting interface is controlled to be in the range of 25-500 milli-amps. Lastly, the cutting tool is moved into and along cutting contact with the work-piece while current flows there-between to electro-chemically deposit the wear reducing agents on at least the contacting interface to reduce cutting tool wear and improve ease of mass removal.

Abstract: An EDM machine for machining a workpiece is disclosed. The EDM machine includes a machine frame having a central stationary machine body and a machining electrode to machine the workpiece. Machining occurs by producing a relative movement in at least one of an X axial direction and a Y axial direction between the machining electrode and the workpiece. The machine also includes a first axial slide for moving at least one of the workpiece and the machining electrode in the X axial direction, and a second axial slide for moving at least one of the machining electrode and the workpiece in the Y axial direction. The first axial slide is mounted in a substantially vertical plane on the machine body for lateral movement in a substantially horizontal direction.

Abstract: Disclosed is a method of depth-specific processing with a small hole electric discharge machine drill. Firstly, a specified processing depth A and tolerance &agr; are registered with a program. Secondary, an origin of initiation of drilling is set on a surface of a workpiece by contacting a tip of an electrode D with the surface of the workpiece at a check point. Thirdly, the electrode is moved to a processing position to process until the specified processing depth. Fourthly, the electrode is moved to a position above the check point. Fifthly, the electrode is moved downward until the electrode contacts the surface of the workpiece, a Z-axis coordinate upon contact is defined as C. And finaly, a condition judgment is made concerning C which is found in the fifth step, as to whether or not |C|≦&agr; is satisfied. If the condition is satisfied, then processing is completed.

Abstract: An electric discharge machining apparatus includes a first movable body (40, 42, 50) movable along the Z axis, a ball screw (34), a motor (30) for causing rotation of the ball screw, a nut (35), attached to the first movable body, threadingly engaging the ball screw, a second movable body (10, 13) movable along the Z axis relative to the first movable body, capable of having the tool electrode attached thereto, and a linear motor (71, 72, 73) for moving the second movable body, for machining a workpiece by moving a tool electrode along a Z axis towards the workpiece while causing an electric discharge between the workpiece and the tool electrode. The linear motor includes a stator (73) attached to the first movable body, and a mover (71, 72) attached to the second movable body. The first and second movable bodies include respective electrode attachment units (50, 13).

Abstract: A machining center includes a spindle, a main table and an NC device for making a machining relative movement between the spindle and the main table. An index apparatus includes a housing mounted on the main table. An index table is supported on the housing for rotation. The apparatus further includes first and second push bars extending into the housing and outwardly of the housing for longitudinal movement, the NC device being arranged to make an extra relative movement between the spindle and the main table other than the machining relative movement, so that any one of the first and second push bars can be pushed and moved longitudinally thereof by the extra relative movement between the spindle and the main table.

Abstract: An EDM machine with a plurality of separate electrodes selectively driven by the same actuator on the same head of the EDM machine is provided. Preferably, all of the electrodes are not used to cut the workpiece at the same time. Rather, the actuator has a drive mechanism, which is preferably servo-controlled, and each electrode is selectively engaged with the drive mechanism to advance and retract only the desired electrode relative to the workpiece. Either the workpiece or the EDM head is preferably manipulated using a CNC positioning system to accurately locate the desired electrode relative to the workpiece.