In the pursuit of obtaining reliable and repeatable cycle times from machine to machine within a multi-machine, production environment, we have outlined the different elements that must be examined and incorporated after having proved them in practice. Let's review them now in summary, without details. It is understood that the make, model and size of the machines must be the same and of the reasonably same vintage. This also applies to using the same type and age of the dielectric fluid. After this, the individual, electrical alignments or tuning of the generator and servo system are the first steps required and are the easiest. While these tune-ups are technical issues that require qualified, factory specialists to perform, they are tests and diagnostics that are considered routine and are easily accomplished by factory service engineers with the proper training, equipment and experience. After this, the continuity of electrode tolerances, including flushing holes must be insured. Accurate flushing holes are required to support consistent flushing pressure from electrode to electrode and machine to machine. Next, we insured accurate flushing pressure by incorporating more accurate pressure gauges and the precision control of needle valves (even if done out of order at the time). We next offered the suggestion of not using the adaptive part of the EDM generator for better parity of machining times. A scary proposition for some, but reliance upon the advice of experienced operators, good equipment and good EDM conditions can make this decision easier than one might think. We closed by describing the demands a repetitive, jump cycle sequence places upon a servo system that is constantly active and engaged. This especially proves that accurate servo response will yield more consistent cycle times, uniform surface finishes and fewer overall problems.
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