What Can It Do?
You may have tried manual tap burners or disintegrators in the past and found them to be lacking. Perhaps your requirements require better accuracy, or finer control. Crude machining processes pose a risk to high value parts, our EDM-101’s electrical discharge machining eliminates that margin of error by providing very fine EDM parameter control along with functions like pecking and positional monitoring not available on conventional tap removal equipment.
Before losing hundreds or thousands of dollars writing off damaged materials, wasted labor, or spending added cost on time-consuming outsourcing, consider integrating our EDM-101 machine as a tool into your operations and protect your time, materials, and labor with every cost-effective broken tap extraction.
If you have a RAM EDM Sinker it’s priority is to run production machining.
Don’t take your expensive CapEx sinker out of production to removal a tap, remove a drill, remove an end mill, extract a screw, perform complete bolt removal.
Instead of tying up your existing Cap-ex EDM consider roughing select jobs, or a subset of a roughing job, on EDM-101 before finishing on your existing EDM for a more cost-effective routing.
Jobs can be performed on your existing Bridgeport or similar knee mill utilizing our unique quill mount. Our quill mount EDM broken tap remover is one of these invaluable upgrades to your existing equipment that quickly pays for itself if you frequently ship out parts that need prompt and damage-free removal.
EDM-101 becomes a symbiotic accessory as it does not interfere with normal spindle function. In fact pre-drilling followed by EDM sinking a shape, such as a hex, can be performed sequentially by any machinist on a Bridgeport.
Could your facility benefit from an economical EDM system that supports broken tap extraction and precision prototyping, rework and even production?
CMW Tech’s EDM-101, launching in 2023, is a new EDM product which bridges the gap by meeting a market need between tap burners and complex & expensive EDM machines. We created this product so machine shops, manufacturing facilities, engineering development and technical education facilities would have the opportunity to utilize EDM capabilities at a cost-effective price-point.
Both developed and manufactured in the USA, EDM-101 is not like anything in the market. EDM-101 satisfies a niche between a Tap burner and an entry-level EDM sinker all at a value point with a breadth of capability unlike anything on the market.
Our versatile EDM product is accessible, user-friendly, and purpose-built for every facility to minimize outsourcing expenses and delays while adding an in-house EDM tool to your capabilities.
Easy to install, and easy to operate EDM-101 is a complete system with a breath of capability from Tap removal to jobs that requires precision machining an EDM simple shape such as a keyway, hex, or shape of your choosing into High Alloy parts, steel, or conductive metal with burr-free finishing and dimensional accuracy and repeatable consistency defined by the electrode shape.
EDM-101 includes a dual filter and pump system to deliver and process Tap / Deionized water making it an ideal shop floor-friendly accessory to your Bridgeport or similar turret-style vertical knee mill. Yes you can EDM with water and achieve amazing results. A Water flushing system is available at launch. EDM-101 also works with all EDM oils, a similar flushing system is planned. Please contact CMW Tech about your application to discuss how we can configure a system for you.
Practical Subset of Capability and Operation found on EDM Sinkers.
Provide electrode based machining previously only available with significant Capital expense. From broken tool removal to sinking simple shapes such as hexes and keyways into precision parts.
Save Time and Money $
Perform select jobs inside shop vs. sending to outside EDM services
Don’t lose control of your schedule, keep parts in your job flow to meet your revenue shipment plan.
Improve Operation Efficiencies $
Complements any machine shop with a practical subset of EDM precision machining capability. Perform roughing and tool removal that may be taking your expensive in-house EDM capital equipment out of production.
Training and Educational
Positive interest from Tech Schools, Community Colleges, and Industry Organizations to promote EDM skillset at an affordable price point.
HEAD ASSEMBLY | Included functionality |
Quill mount bracket | Tool-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 Axis | Full 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 Axis | Sweep 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 | |
Flushing | Integrated spindle port for core flush fluids |
Industry standard 8mm grommets support 0.5-5.0mm flushing electrodes | |
Color display | Easy to observe current active job state .. Complementing Tablet Real Time Display |
ESTOP | Instantly disables motors and EDM voltage output |
Wifi | Self contained Wifi node supports communication with Tablet-App |
FCC compliant | |
End effector | Compliant 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 | |
Attachment | Electrode guide assembly (option) holde industry available small hole guides |
POWER CONTROL UNIT | Included functionality |
Electrical Connections | AC 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 Installation | Robust Welded Steel Assembly Bolts to Bridgeport rear RAM mount |
+ Hanger forks extend through Top cover of PCU | |
Table Top | |
+ Rubber feet standard |
TABLET | Android Tab A 8″ Tablet |
Communication | Wifi |
+ 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 App | 4 Easy to Operate Modes |
SETUP | Initial 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 | |
JOBS | Create 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 | |
RUN | Start / 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 | |
INFO | Monitor FeedRates and other monitored results for Process knowledge |
+ Sensor states, timers, performance counters, etc. show status of system in real time |
FLUID ASSEMBLY | Deionized Water, Distilled, Reverse Osmosis and Tap < 150 uS/cm |
Storage | 20 Gal. Capacity High Density Polyethylene Drum |
+ Recirculatory System | |
Filters | PreFilter : 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 | |
Manifold | T-Slot Mount allows easy adjustment for both Core and Side Flush flow |
+ Integrated pressure gauge feedback for Core flush pressure | |
Pumps | Primary 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 Inhibitor | Recommendation : Uniquely does not increase conductivity of water |
+ Savan RVH-650-1 | |
Cart | Push Cart Dolly by Wellmax, 330 lbs capacity, Swivel wheels |
As you can see from the multifaceted production potential, our cost-effective EDM provides relevant utility for a spectrum of machine shop applications Whether you aim to spend less on broken tap removals and select precision machining EDM jobs… or you would like to introduce multipurpose EDM demonstrations into your curriculum, our economical EDM equipment is worthy of consideration.
The EDM 101’s main use is to remove broken taps and produce basic EDM features such as keyways, and perform precision shape machining such as hexes at a cost effective price point. Machine shops, model shop, training centers and garage shops all have Bridgeport style knee mills that can be enhanced with EDM capability for low volume machining of simple shapes in precision parts.
EDM-101 is the most cost effective answer to Upgrade your classroom environment to teach EDM precision machining.
Trade school, tech shop or community college EDM equipment that not only demonstrates but performs precision machining equals value. Our EDM-101 is the most capable and affordable solution. Your program no longer has to compromise on entry-level EDM products that offer limited to no utility to inform your students the basic EMD process, or worse try to educate based on a text book alone. With EDM-101 EDM education demonstrator in place, knowledge of the EDMing process can be completely taught and tested.