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EDM 101

Your Cost-Effective Solution for Tap Extraction and Sinker Work

The EDM 101 delivers cost-effective tap burning and efficient broken-tap extraction, making it a smart choice for machine shops and tech schools alike. This versatile EDM solution complements existing processes, offering affordable roughing and reliable broken screw removal.

Ideal for entry-level electrical discharge applications, the EDM 101 is user-friendly and compatible with low-volume part production, hex bolts, geometric shapes, and more.

$24,900.00

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EDM 101 Tooling Head and Tablet for Broken Tool Removal, Broken Tap Removal, Broken Stud Removal
EDM 101 Before and After Broken Tap Removal Example

Remove Broken Tools Quickly

Don’t let broken tools and taps slow down production. The EDM 101 removes them quickly and easily, allowing you to continue your product production on-time and on-budget.

With the EDM 101, you can recover parts previously set aside due to broken tools, boosting efficiency, reducing waste, and helping you deliver on time.

Download EDM 101 Data Sheet

Meet the EDM 101

CMW Tech’s EDM 101 combines the simplicity of manual tap burners with the advanced capabilities of automated sinker EDM machines. Designed to meet industry needs for cost-effective EDM ram-style sinker capability, the EDM 101 provides a powerful yet affordable solution.

Using rapid, microsecond pulses to remove tiny fragments, the EDM process is stress-free and leaves a burr-free finish. The EDM 101 mounts easily to any Bridgeport-style knee mill with a quill mount or other rigid structure, allowing precise control of electrode positioning using standard machinist techniques.

EDM 101 Specifications

Repair Valuable Parts and Tools

Skip the Easy Out and carbide end mill—rely on our affordable EDM machine to meet your extraction needs. Easily remove broken drill bits and embedded hex screws, saving on replacement costs with every part our EDM machine restores.

Shape a Greater Variety of Component Types

Whether producing keyways or refining parts after Bridgeport roughing, the EDM 101 delivers precise, repeatable results with every run, enhancing efficiency and consistency across applications.

Cost Savings and Revenue Generation

Save on materials and valuable parts by removing broken tools with the EDM 101. Generate revenue by producing small parts in-house or offering tool removal services to other manufacturers.

CASE STUDY

Tapout Texas Boosts Revenue and Service Capabilities with the EDM 101

Read Case Study

EDM 101 Specifications

Output

  • 120 Volts DC programmable 0.3 through 20 Amps
  • Complete On/Off Time programmable control

Input

  • AC 220-230V -60hz Single Phase (20amps)

Head Travel

  • Z-axis 3.0” (76mm) with .001” jog resolution
  • Theta 0-270 degrees with 0.1-degree resolution
  • Full Z-Pecking control as well as Theta sweep

Tool Removal Range

  • 0-80 to ½-20 equivalent to M1.6 – M13

Electrode Diameter

  • Round .015 to .5 inch (0.38 to 12.7mm)
  • Hex up to 14mm, Keyways: to .375 square

Head

  • Easy access ESTOP switch
  • Integrated LCD displays active job and operational Icons
  • Quill mount Head to Bridgeport or optionally attach head to rigid structure or magnetic base

Working Speed

  • 0.003”-0.03”/min (0.076 – 0.75mm/min)
  • Automatic EDM servo control
  • Results depend on electrode, target material, and cross-section

Power Control Unit

  • Mount to Bridgeport with CMW Ram-Hanger or Tabletop

Flush and Filter

  • Easy maneuver cart with 20-gallon tank; deionized or distilled water
  • Two pumps: low-pressure side and adjustable core flush pressure up to 100 psi
  • Two-stage economical filter system

User Interface

  • Easy-to-use wireless Android Tablet
  • Four operational modes: Setup, Job, Run + Info for feedback
  • Full parameter control to create, edit, save, and retrieve jobs
  • Real-time EDM progress with Auto-stop for depth control
HEAD ASSEMBLYIncluded functionality
Quill mount bracketTool-less Dutch key for easy On/Off & Rotation
 Built in HEAD swivel for veritical orientation
   + 7″ added to the Bridgeport work envelop
   + Rigid design supports additional custom orientations
Z AxisFull 75mm (2.95″) Travel
 Built in Electrical contact detect : XYZ sound annunciator
 AutoStop : Operator selectable Depth (blind) and Material thickness
 Precise positional control
    + Full Up/Down jog control with 0.001″ resolution
    + Easy to customize coarse and fine jog based on your desire
 Full positional control of Pecking
    + Fixed, Surface, and Combined Fix & Surface Pecking
    + Example : 0.020″ peck every 5 seconds
 Programmable electrode wear compensation for repeatable accuracy
 Fully automatic 1.0 micron resolution during EDM operation
Theta AxisSweep range programmable 0-270 degrees
    + Face of round electrode remains flat and predictable
    + Sweep eliminates “tails” from forming when remoiving Taps
        Note :  Other Tap burners require periodic refacing to remove “Tail” that can damage blind holes
 Unique theta offset function supports electrode orientation to 0.1 degrees.
   + Ensures orientation repeatability when job requires multiple shaped electrode operations
FlushingIntegrated spindle port for core flush fluids
 Industry standard 8mm grommets support 0.5-5.0mm flushing electrodes
Color displayEasy to observe current active job state .. Complementing Tablet Real Time Display
ESTOPInstantly disables motors and EDM voltage output
WifiSelf contained Wifi node supports communication with Tablet-App
 FCC compliant
End effectorCompliant with Multiple Chuck Adapters : J1, 5-16/24, 3-8/24, CMW rod and shaped electrode adapters
     Built in referance pin allows accurate electrode changes and re-alignment repeatability
     Adaptor Nut makes for easy on/off adapator changes
AttachmentElectrode guide assembly (option) holde industry available small hole guides
  
POWER CONTROL UNITIncluded functionality
Electrical ConnectionsAC Line Input
    + 220 VAC Single Phase, 20A line
 Separate Positive and Negative Polarity  Ports
    + To Electrode / From Ground return
    + 0.325A to 20A EDM current
    + Precise On & Off time modulation of current according to Job parameters selected (usec resolution)
    + Gap voltage automatically monitored to maintain Electrode position for EDM
    + 120V at Gap
    + Low Voltage contact detect. Selectable in Table Setup
 Shielded DB25
    + Receives Host Tablet commands
    + Outputs position control of Z and Theta axis to support Joging and EDM process
    + Outputs periodic status of all functions for Tablet display
 Pump Cable
     + Pump 1  12V : Side flush using submerged pump in dielectric source
     + Pump 2  12V : Core Flush pressure boosted 5-100psi
 Annunciator notifies and alerts operator with audable sounds
 USB Port 5V charges Tablet
Mechanical InstallationRobust Welded Steel Assembly Bolts to Bridgeport rear RAM mount
   +  Hanger forks extend through Top cover of PCU
 Table Top
   + Rubber feet standard
TABLETAndroid Tab A 8″ Tablet
CommunicationWifi
   + Tablet detects Wifi Node in HEAD during power-up
   + Seemless wireless communication between Tablet and Head for Operations
   + User can change local wifi name as desired
CMW Tech App4 Easy to Operate Modes
SETUPInitial Setup and Manual functional check of Hardware
   + Home : Z and Theta Axis
   + Jog : Z and Theta Axis, with custom resolution adjustment
   + Z-Seek auto detect surface position using low (<5) voltage through electrode
   + XY edge senses surface position using low (<5) voltage thorugh electrode
   + On/Off Side and Core Flush pumps
   + On/Off PCU Internal Chassis and Stack
   + Theta Offset adjustment
   + On/Off Sound Alerts from Annunciator
   + On/Off High Voltage to Low Voltage
JOBSCreate new Jobs with unique ID, Names, and creation dates
   + Duplicate , Rename, and Delete Jobs
   + Load (retrieve) and Backup Jobs on HEAD SD card
 Setup Parameters according the EDM requirements
   +  Depth or Thru EDM Distance
   + Job Notes : Target Material, Electrode Material Shape and Size
   + Maximum Amps to use and On/Off Time for current selected
   + Theta : Sweep and Dither increments, range, and interval
   + Soft Start : Unique current and  displacment control during beginning of EDM
   + Full Peck control : Fixed, and Surface displacment and interval desirred
RUNStart / Stop EDM
   + On/Off selection of Side and Core Flush Pumps
   + Z-Zero : Operator can manually set Z Zero as desired
   + Z Position : : Actual, Z Minimum acieved, Z Min with Electrode Wear Compensation
   + Run Time Message Window : Alerts, and Temperature bar graph
 When EDM not active (Stopped)
   + Full Z and Theta Axis Jog Buttons for conventience without exiting mode
 When EDM active (Started)
   + Graphics showing Msec Counters spent Moving Down and Retracking
   + Graphic animation showing Electrode and Target Materials % Complete
INFOMonitor FeedRates and other monitored results for Process knowledge
   + Sensor states, timers, performance counters, etc. show status of system in real time
FLUID ASSEMBLYDeionized Water, Distilled, Reverse Osmosis and Tap <  150 uS/cm
Storage20 Gal. Capacity High Density Polyethylene Drum
     + Recirculatory System
FiltersPreFilter :  4″ x 14″ Seamless Polyester
    + Course Swarf.. Recommending 5 micron rating
    + 0, 5, 10, 15 micron particle size filters available
    +  Inexpensive (~$6) replacement
    + Mount designed to optimize gravity runoff vs. workpiece height
 Primary Filter : Pentek 10″ 3G Slim Housing Clear
    + Fine Swarf.. Recommending 1 micron rating
    + Inexpensive polystyrene or pleated (~$5) replacement
ManifoldT-Slot Mount allows easy adjustment for both Core and Side Flush flow
    + Integrated pressure gauge feedback for Core flush pressure
PumpsPrimary Submersible : Side Flush Low Pressure
   + 12V Heavy Duty Johnson / Albin Style Marine Bilge
 Secondary  : Core Flush
   + 12V Diaphram Style Booster Modified 0-100psi
   + Pressure is adjustable through CMW valve desgin
 Secondary : Core Flush Vacuum
    + Valving switches Pressure across integraqted Venturi to create vacuum
    + Unique capability pulls swarf through electrode ID reducing side arcing
Rust InhibitorRecommendation : Uniquely does not increase conductivity of water
   + Savan RVH-650-1
CartPush Cart Dolly by Wellmax, 330 lbs capacity, Swivel wheels

Let’s Chat About the EDM 101

To learn more about the EDM 101 and other CMW Tech solutions, please complete the form. If you wish to speak with our sales team now, please call 1-215-721-0120.

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