How to drill a 0.2 mm diameter hole in tool steel?


When you need to drill small holes, finding a drill is not th eproblem but drilling is the problem. Now with our Novidrill400-II you can drill holes of 0.2 mm in ANY conductive material. The machine is affordable and can drill holes from 0.2 till 3 mm with the standard drill holder. Other sizes, bigger and smaller are also possible to drill with an extra toolholder.

 

Drilling an 18 mm deep hole with an 0.2mm diameter at a customer.  NOn contact drilling. Deep hole drilling with standard affordable machine.

 

Novidrill400-II testing capability of the small 0.2 mm  diameter drilling at a customers place.

 

How does a 70% reduction in Wire EDM operation costs Sound to you?


Novicut M-II New series

The price of a wire EDM machine is nothing compared to the cost of wire over the life of the machine. “Wire is the single highest expense in operating a wire EDM.

One of the highest operating costs for any wire EDM is the cost of the wire the machine consumes during a cut. Although wire consumption rarely appears as a topic of concern for most wire EDM users, the financial benefits of owning a Molybdenum wire-cutting machine can be critical to a manufacturer’s bottom line.

EDM brass/copper wire, at its current cost of approximately 10-15 Euro a kilo, is the single highest cost related to the use of WEDM technology. The faster a machine unspools wire, the more it costs to operate that machine.

On average, most Copper/brass WEDMs unspool wire at a rate of 750 grams to 1.1 kg per hour. And although these higher rates can be reduced by slowing the unspool speed, manufacturers must then deal with increased breakage of the wire with additional adverse effects to speed, accuracy and surface finish. Under these unreliable conditions, increased cycle times and maintenance can oftentimes negate or even surpass the cost saving of slower wire feeds.

Cutting this high operating cost by 40 percent to 50 percent equates to an EDM wire saving value of about €8,000 to €10,000 per machine, per shift, per year! However, if this cost saving in consumables is offset by high maintenance costs and lost production time, there is no advantage. The ability to improve EDM wire saving while increasing productivity through reliability can have a significant impact on overall profit.

Investing in a Novicut M-II wire EDM will allow you to regain control over your EDM department and generate good profit.  When you are facing extended lead-times and part inconsistencies due to outsourcing and the unreliability of your older machines, then it’s urgent time to think on an investment that run unattended throughout the day, over nights and even weekends. We can ensure that quality will be again to your standards and saving money hand over fist on operational costs will be again in reach.

Although wire consumption rarely appears as a topic of concern for most wire EDM users, the financial benefits of owning a low-wire-consumption machine can be critical to a manufacturer’s bottom line. With the revolutionary Molybdenium wire cutting system with zirconium guiding wheels, you will be able to have savings of up to 70 percent in many applications while maintaining precision and surface quality (Ra<0.8µ).

Because Novick builds mechanical accuracy into these machines, the on-board computers are required to perform axis movement error compensations less frequently. This allows the control to address higher priorities, like activating Novick patented Fuzzy logic technology and performing the multitude of calculations required for it to work properly.

EDM wire, at its current cost of approximately €12-15 a kg, is the single highest cost related to the use of WEDM technology. The faster a normal machine unspools wire, the more it costs to operate that machine. For shops that run a WEDM for 2,000 hours per year, or one full shift, settings can experience about €10,000 each year in EDM wire saving per machine.

NOVICUT 350 M II

HIGH-SPEED EDM DRILLING

Do you want to expand Your Hole making Capabilities? Look into our Novidrill range


In need of producing Smaller, Deeper, More Precise Holes?

Demand for smaller, deeper and more precise holes produced as fast and as consistently as possible has created a need for more advanced, new Electrical Discharge Machine (EDM) drilling technology in hole making operations.

Here are some tips on how to select the EDM drilling system that will help your shop achieve these holes making goals.
  1. Look for an EDM system that is fast, reliable and simple to operate. It should have enhanced drilling capabilities for extremely small hole sizes, but at the same time maintain good surface finish quality and accuracy at greater depths. Considering some of to-day’s applications, it’s important to look for a system that can drill a 15-mm deep hole as small as 0,20 mm in diameter in hardened steel and at the same moment to be able to drill a cooling hole of 2,5 mm in diameter 250-mm deep in mould steel, and this with minute variations in size and straightness from its entrance to exit.
  2. Most experts recommend selecting an EDM drilling system that utilizes the latest in digital generator technology. Digital generator technology, gives EDM drilling machines more precise spark control. It is this functionality that also helps reduce electrode wear. For optimal productivity, the goal is to generate as many holes as possible or drill as deep as required using the least quantity of electrodes. Thus, the more a generator can help reduce electrode wear the better. Plus, less wear on electrodes allows them to cut faster and more accurately by eliminating the “bullet nosing” of their electrode tips.
  3. Seek out an EDM drilling system that can be operated by any person in the workshop, without any high-level programming skills. Simplicity is here the rule.
  4. High-quality surface finish capability is a must. A growing amount of shops now use EDM drilling machines for generating finished holes that will not require any secondary finishing operations.
  5. Keep in mind that uneven wear increases a drilling electrode’s tendency to “walk” off centre, resulting in crooked and angled holes instead of straight ones. Because they help reduce wear, Supper high pressure coolant/flushing system thus prevent such a scenario and contribute to producing straighter holes and ones that can be held closer to size from top to bottom. For instance, a 200 mm-deep hole drilled with a 1 mm electrode on a digital generator-equipped EDM system will vary in size from top to bottom, usually less than 0,025 mm.
  6. Find an EDM drilling system that provides control over heat-affected zones for generating surface finishes comparable to those typically attained using a wire-type EDM. Such surface finishes are possible only with a super high pressure coolant/flushing system with sufficient debit to take the heat immediately away from the working zone.
  7. High pressure dielectric fluid is one of the most important factors, which is usually supplied to the gap through the bore of tubular electrodes.  The use of a pneumatic intensifier pump results in drilling parts up to 50% faster and with lower operating costs as much as 40%! Pneumatic activated high-pressure pumps produce 30% more pressure than a standard water jet pressure pump, resulting in a 40-50% increase in productivity for many materials. Compared to a water jet pump, typical operating pressures uses 30% less water, 30% less power, and up to 50% less electrode consumption, resulting in a 40% reduction in operating costs. Being green with energy does not only spare the nature but also your wallet.
  8. Request a non conductive table of high precision, by preference Granite.  A work-table from granite offers big advantages:
    • You can’t drill into the table
    • table resist to corrosion of the dielectric liquid: doesn’t get rusty
    • keeps the super precision and guarantees a better flatness
    • parts cannot be welded to the table due to bad contact with table

Conclusion

Today’s technically advanced EDM drilling systems essentially put hole making accuracy in the technological hands of the machine tool. Modern EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality surface finishes.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Our Novidrill-400-II is offering on all these requested criteria a positive answer and this for a VERY attractive budget!

The Basics of High-Speed EDM Hole Drilling


High-speed EDM hole drilling was designed especially for fast, accurate small- and deep-hole drilling applications. Small holes that were once almost impossible to drill by conventional machine tools are now being performed with ease. With the capability of drilling through virtually any conductive material, the use of this technology is continually expanding.

Initially shops were using this technology specifically for start holes in wire EDM jobs. Because of this technology, workpiece materials are being sent out for heat treating prior to drilling the start hole. This removed two major problems: having to program, locate and drill the holes by conventional machine methods in the “soft” workpiece prior to heat treat and by heat treat the workpiece before drilling, all the stresses are being removed prior to the drilling process. As this process became more widely known, test burns were being done in more than just hardened tool steel; tungsten carbide, aluminium, stainless, titanium, brass and inconel were being tested. High-speed EDM hole drilling applications began to expand to mould and part manufacturing-injection nozzles, oil drain holes, hydraulic cylinders and dowel pins, as well as turbine blades, ball bearings and safety wire holes in hex nuts, to name a few.

The EDM Drilling Process

The process consists of using a precision tubular electrode (generally brass or copper) mounted into the drill chuck located on the “Z” axis and held in location on top of the workpiece by the ceramic guide. The top of the workpiece is located and the drilling depth is set. The electrode rotation is turned on and the deionized water solution, which is pressurized between 30 and 120 kg/cm2, is sent through the tubular electrode as a flushing agent. The power supply parameters are set-which normally consist of on-time, off-time, peak current and amount of capacitance. At this point, the discharge is turned on to begin the drilling cycle. At the end of the drilling cycle, the discharge is turned off and the “Z” axis is retracted above the workpiece.

Drilling Times

Drilling times are based on the hole size and type of material.

A few samples of possible speeds for reference:

Material Electrode Dia. Drill Depth Machining Time
Alloy Tool Steel 0,5mm 12,5mm 25 to 35 seconds
0,5mm 25mm 50 to 60 seconds
1,0mm 25mm 55 to 65 seconds
Tungsten Carbide 0,5mm 12,5mm 4 to 5 minutes
0,5mm 25mm 8 to 9 minutes
Aluminum 0,5mm 12,5mm 40 to 50 seconds
0,5mm 25mm 90 to 100 seconds
1mm 70mm 3 minutes

 

Observing the mentioned times explains why high-speed EDM hole drilling has become an alternate method to conventional machining in mould manufacturing. In addition, this method of drilling produces burr-free holes, which results in the elimination of secondary deburring processes.

Today, Novidrill 400-II can use distilled water/tap water as the flushing agent, which opens new and very economically application possibilities in the medical field. With continued improvement in this technology, more and more applications are being seen on the horizon-it has become a whole new method of manufacturing moulds and parts.

high speed edm

High precision wire cut at very low cost with the new Novicut M-II line


NEW Novicut M 650-II precision and accuracy wire cut test

Executed: 2017-november

Material: D2 Tool Steel | 1.2379 | X153CrMo12 | SKD11

Cold Works D2 tool steel is a high carbon, high chromium tool steel (12% chrome) with extremely high wear resisting properties, heat treatable to 60-62 Rc

Electrode : Wire of 0.18mm, Molybdenium wire 99.8%


Results :

  • Average Surface roughness : Ra = 0.76 µm
  • Pitch accuracy : 14µm
  • Shape accuracy : 9 µm

 

Procedure :

  • Multi-cutting function 4 cuts
  • Best roughness Ra<0.68 µm
  • Worst Roughness Ra<0.78 µm
  • cutting speed hit 315mm2/min at highest wire speed at first cut.

With the new advanced and patented pulse power eco generator specific for molybdenum we get much lower loss of wire (electrode wear). The diameter of a 0.18 mm wire, reduced with 0,007mm in 200.000 mm2 cutting (5 shifts of 8 hour working). This keeps the precision of the each cut at the lowest cost available!

Do you want to expand Your Hole making Capabilities?


In need of producing Smaller, Deeper, More Precise Holes?

HIGH-SPEED EDM DRILLING

Demand for smaller, deeper and more precise holes produced as fast and as consistently as possible has created a need for more advanced, new Electrical Discharge Machine (EDM) drilling technology in hole making operations. Here are some tips on how to select the EDM drilling system that will help your shop achieve these holes making goals.

  1. Look for an EDM system that is fast, reliable and simple to operate. It should have enhanced drilling capabilities for extremely small hole sizes, but at the same time maintain good surface finish quality and accuracy at greater depths. Considering some of to-day’s applications, it’s important to look for a system that can drill a 15-mm deep hole as small as 0,20 mm in diameter in hardened steel and at the same moment to be able to drill a cooling hole of 2,5 mm in diameter 250-mm deep in mould steel, and this with minute variations in size and straightness from its entrance to exit.
  2. Most experts recommend selecting an EDM drilling system that utilizes the latest in digital generator technology. Digital generator technology, gives EDM drilling machines more precise spark control. It is this functionality that also helps reduce electrode wear. For optimal productivity, the goal is to generate as many holes as possible or drill as deep as required using the least quantity of electrodes. Thus, the more a generator can help reduce electrode wear the better. Plus, less wear on electrodes allows them to cut faster and more accurately by eliminating the “bullet nosing” of their electrode tips.
  3. Seek out an EDM drilling system that can be operated by any person in the workshop, without any high-level programming skills. Simplicity is here the rule.
  4. High-quality surface finish capability is a must. A growing amount of shops now use EDM drilling machines for generating finished holes that will not require any secondary finishing operations.
  5. Keep in mind that uneven wear increases a drilling electrode’s tendency to “walk” off centre, resulting in crooked and angled holes instead of straight ones. Because they help reduce wear, Supper high pressure coolant/flushing system thus prevent such a scenario and contribute to producing straighter holes and ones that can be held closer to size from top to bottom. For instance, a 200 mm-deep hole drilled with a 1 mm electrode on a digital generator-equipped EDM system will vary in size from top to bottom, usually less than 0,025 mm.
  6. Find an EDM drilling system that provides control over heat-affected zones for generating surface finishes comparable to those typically attained using a wire-type EDM. Such surface finishes are possible only with a super high pressure coolant/flushing system with sufficient debit to take the heat immediately away from the working zone.

Conclusion

Today’s technically advanced EDM drilling systems essentially put hole making accuracy in the technological hands of the machine tool. Modern EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality surface finishes.

Check out our perfect and affordable solution : novidrill 400-II new model with granite table, super high pressure coolant pump.

 

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