MATERIAL: 318 Stainless Steel
SPECIFICATIONS: 50mmØ x 0.15mm disc featuring a 0.020mm thru-center hole, 50mmØ x 0.25mm disc featuring a 0.040mm thru-center hole, 50mmØ x 0.25mm disc featuring a 0.060mm thru-center hole, 50mmØ x 0.25mm disc featuring a 0.080mm thru-center hole, 50mmØ x 0.25mm disc featuring a 0.100mm thru-center hole
A 1.0mmØ x 50mm electrode featuring a 0.014mmØ pure tungsten rod tip was mounted to the spindle collet holder of a Makino EDFH1 sinker EDM. A precision ground copper tungsten dressing block was mounted to the machine's table. The EDFH1's Auto Precision Dressing macro was used to dress electrode diameters of 0.014mm, 0.027mm, 0.047mm, 0.068mm, and 0.086mm respectively. Profile projector microscope measurements were performed on the dressed tooling prior to the machining of each hole to ensure accuracy.
The EDFH1 machined each hole in approximately 10 minutes using a 1,000RPM spindle rotation and jump machining. Upon completion, all holes were inspected for quality using a tool maker microscope under 600x magnification. To ensure errorless inspection, the microscope was subjected to the same environmental conditions as the EDFH1.