What is Die Sinking?

Die sinking is a process used to machine or create a specific size or shape cavity or opening in steel blocks. The openings in the steel blocks can then be used to mold plastic into different shapes. Such openings may also be used when doing forging, either hot or cold, or for coining or die-casting. Most often, die sinking is used to place names, numbers, and other sources of information onto metal. It can also be used to place such elements on a piece of wood, leather, or many other materials. The process for die sinking is fairly simple and something that anyone can do with a few simple tools. There are also larger machines that can help with the process, but these machines come with a price tag. The process of die sinking begins by obtaining a piece of sheet metal and cutting out a shape. For instance, the shape may be a shield or name tag. When doing the process of die sinking, it is important to use a piece of sheet metal for the project that is at least 1/64 of an inch (0.4 mm) thick. Once the shape has been placed on the piece of sheet metal, it will need to be cut out. To do this, a chisel and hammer or otherwise special piece of equipment for cutting sheet metal is used. Once the piece has been cut out, it is necessary to file the rough edges down.

What is sheet metal?

Sheet metal is metal formed into flat sheets through a rolling, extrusion, or hammering process, depending on the type of metal and how it will be used. This material is available for a wide variety of tasks, from installing metal flashing on roofs to building space ships. Companies involved in sheet metal production typically make an array of gauges and grades to meet different needs, and it is also possible to custom fabricate particular types by special request from customers. The gauge of a sheet metal product refers to the thickness. Consistency of metal products can vary and some may be very even, while others may have a slightly more coarse thickness with bumps and lumps. Usually rolling processes maintain a very smooth state, with an even composition. Different nations have their own standardized gauging systems, depending on the system of measurement they use. Grading is a measurement of quality. Each type of metal has its own grading scale, referring to purity, corrosion resistance, and other traits that may be of importance for various metals. High grade sheet metal is more

expensive, as it is of higher quality and tends to be more versatile. Lower grades are less costly and may be suitable for many applications, unless a project has very narrow tolerances or specific needs. When sheet metal is being used as a conductive material, for example, it needs to be of good quality to prevent problems with the product.

WHAT IS CORROSION?
Corrosion is a process that takes place when essential properties within a given material begin to deteriorate, after exposure to elements that recur within the environment. Most often, this deterioration is noticed in metals and referred to as rust. What happens in this case is the chemical reactions that are set up by an exposure of the electrons in the metal to the presence of water and oxygen. As an example, a tin roof is exposed to the wind and the rain.

Die Sinking EDM (ELECTRICAL DISCHARGE MACHINING) machine

EDM machines designed to facilitate the automation of work of every kind, with lower outlay cost. They can incorporate a 40-position electrode changer ( 51 mm 2 inches). A newer, faster, more powerful ONA-S64 CNC, with Windows-based platform, enabling an Ethernet connection allows for reports on machines performance to be sent to mobile phone or PC. New function A-SPACE (Axis for erosion in SPACE). With this function, any programmable CNC erosion function (spheres, taper machining, orbital machining, vectors, etc.) can be carried out in any spatial direction. New module 3D SETUP that includes an extensive set of automatic measurement cycles (automatic balances in any direction of the space, a utomatic alignment of the axis-machine to the axis-piece, etc.) CNC with Expert Erosion System that ensures 100% performance without supervision (with surface finish to VDI =0 - Ra 0.10 m). The mechanical design of the fixed bedframe allows wide travels on the X and Y axes, a high load capacity and high stability. Large cost savings. The filter fitted in the NX machines is totally automated and guarantees over 10,000 hours of operation with zero maintenance costs. Filtering quality is excellent (1 m).

Die Sinking EDM Machine

CNC DIE SINKING EDM MACHINE

Machines designed to facilitate the automation of work of every kind, with lower outlay cost. They can incorporate a 40-position electrode changer ( 51 mm 2 inches). A newer, faster, more powerful ONA-S64 CNC, with Windows-based platform, enabling an Ethernet connection allows for reports on machines performance to be sent to mobile phone or PC. New function ASPACE (Axis for erosion in SPACE). With this function, any programmable CNC erosion function (spheres, taper machining, orbital machining, vectors, etc.) can be carried out in any spatial direction. New module 3D SETUP that includes an extensive set of automatic measurement cycles (automatic balances in any direction of the space, a utomatic alignment of the axis-machine to the axis-piece, etc.) New SAAC system that maximizes generator performance in erosion work involving evolutive surface electrodes. It is particularly apt where the workpiece has little area at the outset. CNC with Expert Erosion System that ensures 100% performance without supervision (with surface finish to VDI =0 - Ra 0.10 m). High-speed pulse technology, which allows to get the shorter machining times in jobs that involve very difficult flushing, more homogeneous finish on large surface areas (VDI 20 - Ra 1.00 m on 225 cm

- 35 in 2 ) and very deep grooves can be machined, with the highest quality and precision guaranteed (VDI 20 - Ra 1.00 m up to 100 mm 4 inches).

CNC Die Sinking EDM Machine

How to Increase the Process Speed of Die Sinking EDM

An increase in productivity of approximately 30 percent, and up to 100 percent with pre-milled molds, is possible with new EDM technology. Developments in the EDM process and its technology along with improvements in accuracy, automation and micro-moldmaking technology can pay enormous dividends to the domestic moldmaking industry.

Speed Is Not the Solution

Increasing drive speed is one solution to improving the speed of die sinking EDM. In this way the unproductive times for lifting movements are reduced;

however, the gain in speed is limited to small electrodes and very deep cavities. In addition, above a certain speed the electrode wear is considerable, and very high axis speeds result in extreme strain on the mechanism, make the machine more expensive and shorten its working life. Therefore, it is wrong to believe that a general increase in the process speed is only to be achieved by rapid lifting movements. The contribution of fast axes to the machining process is just one supplementary aspect to a complex interaction that encompasses the generator, process control, gap width regulation and the mechanism. Die sinking EDM requires intelligent flushing.

Sinker EDM Machining Process

The sinker EDM machining (Electrical Discharge Machining) process uses an electrically charged electrode that is configured to a specific geometry to burn the geometry of the electrode into a metal component. The sinker EDM process is commonly used in the production of dies and molds.

How Sinker EDM works

Two metal parts submerged in an insulating liquid are connected to a source of current which is switched on and off automatically depending on the parameters set on the controller. When the current is switched on, an electric tension is created between the two metal parts. If the two parts are brought together to within a fraction of an inch, the electrical tension is discharged and a spark jumps across. Where it strikes, the metal is heated up so much that it melts. Innumerable such sparks spray, one after the other (never simultaneously) and gradually shape the desired form in the piece of metal, according to the shape of the electrode. Several hundred thousand sparks must fly per second before erosion takes place.