EDM - Electrical discharge machine

EdmGuru

Joined Aug 21, 2018
47
Hi Rung Lawprayoon.
Your best bet is to send them a pm but shortbus hasn't been around on here for a while, he disappeared on the 15th of Dec last year, then appeared on here on the 2nd Feb this year for 1 day and hasn't been seen since? Hopefully he's on holiday somewhere.nice.
 

Thread Starter

shortbus

Joined Sep 30, 2009
10,050
Hi Rung Lawprayoon.
Your best bet is to send them a pm but shortbus hasn't been around on here for a while, he disappeared on the 15th of Dec last year, then appeared on here on the 2nd Feb this year for 1 day and hasn't been seen since? Hopefully he's on holiday somewhere.nice.
Sorry that I haven't been here much. Was in a hospital, University Hospital in Chardon, OH ~45 miles from my home, the local hospital didn't know what was the problem so they sent me there. Ended up it was a massive PE that was putting pressure on my heart and my oxygen level was in the 60% range. So have to be on oxygen now. They also diagnosed my chronic pain in joints and muscles, lupus. Was in the hospital for 5 days the week before Christmas.

Then my wife got sick and was in the hospital twice in January. Then my middle son, who has had a crack addiction over dosed because the crack he got also had Fentanyl mixed in with it, was in the hospital on life support and had a massive stroke. They said he would never have a life outside of a nursing home and may never come out of the coma. So we had them pull the life support and he was sent to Hospice was in there for 10 more days before passing.

Hope this year starts to get better soon.
 

MisterBill2

Joined Jan 23, 2018
27,600
Sorry that I haven't been here much. Was in a hospital, University Hospital in Chardon, OH ~45 miles from my home, the local hospital didn't know what was the problem so they sent me there. Ended up it was a massive PE that was putting pressure on my heart and my oxygen level was in the 60% range. So have to be on oxygen now. They also diagnosed my chronic pain in joints and muscles, lupus. Was in the hospital for 5 days the week before Christmas.

Then my wife got sick and was in the hospital twice in January. Then my middle son, who has had a crack addiction over dosed because the crack he got also had Fentanyl mixed in with it, was in the hospital on life support and had a massive stroke. They said he would never have a life outside of a nursing home and may never come out of the coma. So we had them pull the life support and he was sent to Hospice was in there for 10 more days before passing.

Hope this year starts to get better soon.
Shortbus, , My deepest condolences on the loss of your son. I can't imagine the pain. I hope the other conditions heal in spite of the diagnosis. So I wish you and your wife a good recovery, somehow.
 
Sorry that I haven't been here much. Was in a hospital, University Hospital in Chardon, OH ~45 miles from my home, the local hospital didn't know what was the problem so they sent me there. Ended up it was a massive PE that was putting pressure on my heart and my oxygen level was in the 60% range. So have to be on oxygen now. They also diagnosed my chronic pain in joints and muscles, lupus. Was in the hospital for 5 days the week before Christmas.

Then my wife got sick and was in the hospital twice in January. Then my middle son, who has had a crack addiction over dosed because the crack he got also had Fentanyl mixed in with it, was in the hospital on life support and had a massive stroke. They said he would never have a life outside of a nursing home and may never come out of the coma. So we had them pull the life support and he was sent to Hospice was in there for 10 more days before passing.

Hope this year starts to get better soon.
So sad to hear that. But at least he had a happy life, he was quite lucky to be your son.
And at least he died in happiness.
 

Thread Starter

shortbus

Joined Sep 30, 2009
10,050

EdmGuru

Joined Aug 21, 2018
47
Hi Roong, I hope you are well.

I’ve read through your eBook and recommend the following, also no offense is intended:

The first part about safe practise when using a high D.C. voltage is okay but a bit lengthy, maybe it’s better to just use a more standard disclaimer and avoid the effects descriptions of D.C. verses A.C. voltage on the human body.

In chapter 1 you state that you have not found anyone on YouTube using a stepper motor successfully for an EDM sinker? My stepper motor EDM on YouTube works well, It has a fast stable burn, with low electrode wear and also has anti arc function and auto Z axis retract when the depth limit switch or stop switch is tripped. Part 1
Part 2
Anti arc
My EDM has been further improved since the making these videos. Also My Engines on YouTube successfully redesigned the Ben Fleming EDM to get a stable machine with low electrode wear.

Also you state that your machine has the smallest footprint on Earth? My Easy-Peasy D.C. motor version of an EDM is only the size of a standard PC case and a small drill stand, which is maybe a bit smaller than your machines footprint?

The next part about using transistors as a switch etc is a bit overcomplicated for this machine build and should be shortened and reworded as most people, in my opinion, who are interested in building a sinker EDM will either be confused by the description or already know how a transistor works and disagree with your circuit design etc suggesting different ways or even using an ic type solution. It’s much better to just state that “this is the way I designed the circuitry for this EDM to work” and leave it at that.

Chapter 2 and 3 are largely good but I would never use any P channel transistor or mosfet in any of my circuit designs, especially in a push pull circuit as they don’t give a true output square wave form on their output, which leads to increased electrode wear. I’m interested in your design of current limiting in the power generator. I’ll model a simulation in LTspice to check the output wave form etc.

Chapter 4 is also basically good but again a bit overcomplicated for the beginner, also your stepper motor sense and hold circuit, I feel is not necessary, if you use an op amp instead of the LM393 comparator, I know an op amp doesn’t switch as fast as a comparator ic but they will still switch faster than your max pulse frequency so are okay to use.

I hope that you find my comments on your machine helpful and I wish you every success in the future with it.

Cheers.
 

EdmGuru

Joined Aug 21, 2018
47
WOW! You have done what I was trying to do but didn't have the knowledge to implement, you are the man! If this was available years ago I would have a working machine today. Your book is the best one I've ssent, thank you for it.
Hi Shortbus I hope you are well.
It's never too late to complete your EDM design. Let me know if you need any help with it, I'll be glad to help.
Cheers.
 

roong

Joined Feb 11, 2017
59
Thank you for reading , I thought you using a DC motor. By the time I wrote chapter1 your videos have not come out yet. Like you said I also feel my book is lengthy, I must admit that I am poor in description things even though I try hard which may be my inferior in nature, luckily I am not a teacher.
Time for me to rewrite.
your quote " especially in a push pull circuit as they don’t give a true output square wave form on their output, "
Mine output doesnt need to be a square output. Ideally, slow raise and sharp fall is what every machine need. My topology give slow raise but compromise on fall.
You also quote " also your stepper motor sense and hold circuit, I feel is not necessary ". Wow, I spent years to solve that problems, I thought that circuit was gold for me to be proud. My problem is 6KHz proprogates to stepper driver. The driver is strung. May be I have to peek at someone else.
you also quote " which is maybe a bit smaller than your machines footprint? " I challange that, with the same size of machine who can cut with bigger electrode. The reason half of your energy must be dissipate by MOSFETs.
 
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MisterBill2

Joined Jan 23, 2018
27,600
You could start each chapter with three sections: an OVERVIEW, followed by DETAILS, ending with REALLY DETAILED DETAILS. I did that with a service manual and it worked very well. The service people really appreciated the REALLY DETAILED DETAILs, the manager just looked at the overviews.
 

EdmGuru

Joined Aug 21, 2018
47
Thank you for reading , I thought you using a DC motor. By the time I wrote chapter1 your videos have not come out yet. Like you said I also feel my book is lengthy, I must admit that I am poor in description things even though I try hard which may be my inferior in nature, luckily I am not a teacher.
Time for me to rewrite.
your quote " especially in a push pull circuit as they don’t give a true output square wave form on their output, "
Mine output doesnt need to be a square output. Ideally, slow raise and sharp fall is what every machine need. My topology give slow raise but compromise on fall.
You also quote " also your stepper motor sense and hold circuit, I feel is not necessary ". Wow, I spent years to solve that problems, I thought that circuit was gold for me to be proud. My problem is 6KHz proprogates to stepper driver. The driver is strung. May be I have to peek at someone else.
you also quote " which is maybe a bit smaller than your machines footprint? " I challange that, with the same size of machine who can cut with bigger electrode. The reason half of your energy must be dissipate by MOSFETs.
Hi Roong. I’m glad that you weren’t offended by my comments on your EDM design.

The stepper motor sense and hold circuit I feel is not necessary because all that’s really needed there is to take the output voltage from a voltage divider circuit and create a basic peak voltage hold with time delay circuit, which is only a diode, a capacitor and a resistor. The capacitor and resistor are set in parallel which creates a small RC time delay, so that the peak voltage is only held for a short amount of time, and this output is to an opamp, whose output will then be okay to drive a stepper motor controller such as a TB 6600 or the like.

I would simply use the controllers DIR pin for the up/ down and the EN pin to pause the Z axis.

My comment on the footprint of your machine was related to its physical size and not about its efficiency, which I admit with my design is not good as I use wire wound power resistors to limit the output current.

Overall EDM efficiency is not crucial to the home builder; it’s the end product or result that counts.

Your EDM power generator is of the RLC type design which is normally used on a WEDM and not an SEDM so electrode wear will be a problem, so with that in mind I counter your challenge with a machine detail test. I’ve already shown the small copper coin detail results of my machine designs in my videos. I’ll be interested to see a similar test, using a copper coin, done on your machine for comparison.

Cheers.
 

roong

Joined Feb 11, 2017
59
Hi EdmGuru

Your sample and hold is crude, but I afraid it may effect my motor response time. Anyway if it works it works. Good for you.
I have to admit that your EDM coin is indeed very good just like real machines in a mould shop I used to see years ago. I believe I can do close to that but I have to change from my dirty diesel with a clean EDM oil. And may be another disadvantage in my machine, I choose the main voltage 100vpeak instead of 55Vpeak, which is quite high, Higher main voltage means a little more wear but only this high voltage you can cut carbide like W-Co which I want. Try cutting it on your machine you will hardly go anywhere. My video on cutting carbide was only my second attempt. Now it is better.
Another thing about using 100V is that arcing never occur to me. When I heard that you build arcing protection circuit, I wonder " What on earth he talking about". I never known that it could be a problem. Later on I think that you may using so low voltage. This machine works like Eltree EDM machine in the late 70s to early 80s.
But for the wear, you will be surprise, it isn't what you think. WEDM has high wear rate because zinc component in the wire not because RLC.
Now I has been aways from my machine, as I am taking care my old mom(92). She barely walk. I am excited to take your challenge, a challenge from a real guru, but will take some time and don't expect that I will use coin because there isn't copper coin around here any more. Also I don't think I will win but you will surprise how very close I can do.
Is that your coin a high quality copper. Copper rod I bought from around here (Bangkok), if it cheap it has high wear rate because it is not pure. Expensive one has better wear rate.
 
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