EDM: the right arm in gear prototyping

dicembre 20, 2023

In the world of gears, prototyping proves essential to evolve and validate designs, requiring speed without compromising precision. EDM is the answer if you also have projects of this type. Using this technique guarantees millimetric precision quickly and accelerates the path to moving from the idea to a tangible prototype.

What is electrical discharge machining?

EDM is a machining technology and uses electrical discharges to remove material from a workpiece. This process takes place in a dielectric liquid which isolates the discharges and prevents the formation of waste. The precision and ability to work on complex materials make it ideal for gear prototyping.

Its operation is based on:

Electric field: A generator creates an electric field between the electrode and the workpiece. When this reaches a certain threshold, electrical discharges occur.
Intense heat: the discharges generate intense heat that melts or vaporizes the material at the point of contact between the electrode and the workpiece.
Material Removal: Molten or vaporized material is removed from the dielectric liquid, maintaining process accuracy.

Advantages and disadvantages of EDM in gear prototyping

Among the countless advantages we have decided to report the most interesting ones here:

Production without specific tools: this technique gives the possibility of creating prototypes without the need for dedicated tools, reducing complexity and initial costs.
Reduced lead times: production times are usually faster, which allows for faster development cycles.

However, this technique also has some disadvantages that must be carefully evaluated before considering it for your project:

High operating costs: Due to the high precision and longer execution times, costs may increase.
Limited applicability in production: given the high precision it is more recommended for the prototyping phase, rather than for mass production.

Application and practices of EDM in gear prototyping

This technique is well suited to be applied to the prototyping of some categories of gears:

With Internal and External Teeth: Can be used to create versatile gears with internal and external teeth.
Grooved and involute: it is very valid as a technique due to its versatility in exploring solutions with different tooth profiles.

As underlined several times, high precision is a guarantee of this technique, in fact we recommend it and use it in projects that have prototypes with detailed tolerances.

EDM delivers precise prototypes quickly, optimizing initial gear development. While it has higher operating costs, its precision and speed make it a valuable tool for prototyping innovative solutions. The continued evolution of this technology could further expand its applications in the gear field.

Are you ready to explore new frontiers in prototyping?

EDM: the right arm in gear prototyping

What is electrical discharge machining?

Advantages and disadvantages of EDM in gear prototyping

Application and practices of EDM in gear prototyping

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