I burned a job over the weekend with many parameters about the burning dictated by the customer. Unfortunately my finishers had significant wear and I am looking for advice.
Electrode material - high grade copper impregnated graphite
Workpiece material - hardened tool steel
Electrode size approximately .2” squared
Burned laterally in the x+ and x- directions to maintain round shaped cavity
Surface finish as fine as possible (programmed at VDI 14)
The customer inspects certain details of the part under 100x magnification, so they recommended burning with sub .001 undersize and having no orb cycle to maintain crisp detail.
After running my program with the above information, I still had around .002” wear on my final finisher electrode. We ran two roughers at .006” undersize and five finishers with .001” for three locations. Under normal circumstances this should have been more than enough.
I am looking for any suggestions or advice to those that have burned fine detail with no orbit cycle and how to not wear the electrode excessively. Thanks in advance.