Actually, making an EDM attachment for a milling machine is really quite easy. Some years ago, I wanted to get into the
guts of a microwave oven to modify it for other uses and it was buttoned up with Torx No-Tamper screws. I could not get the
appropriate drivers anywhere (now they are easily available) so built up an EDM setup. It was not the fastest thing in the
world, but did cut the super hard steel very well with high precision.
Chuck, I'm sure you could cobble up a similar setup in an afternoon or two. There is no problem if you feed very slowly,
except the production rate is low. Doing this eliminates the need for FB loops on the axes.
Best,
-John
Chuck Harris wrote:
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Hi Lothar,
The electrode could be something as fancy as a CNC made
graphite model, or it could be something as simple as
adding a little plating to the original plastic gear.
There is no intrinsic reason that an EDM machine should
need 3 phase power, the power requirements for one that
could handle a part this size are very modest... well under
50 watts.
I generate my own 3 phase in my shop. It is easy to do,
and all you need is a big 3 phase motor, and some simple
control components to get it started.
As John said, a silicone mold of the original gear would
be the easiest way.... Damn!.. I wanted an EDM machine.
-Chuck Harris
lothar baier wrote:
i was eyeballing a EDM for a bit but unfortunatly dont have enough floorspace right now, another problem is that most
EDMs require 3phase current which i dont have out here. There are some benchtop type hansved edms on ebay every once
in a while. Another issue it that you need to have a electrode that resembles the form of the gear made of graphite
or copper and usually those are CNC machined parts
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