Drill through anything (conductive) with Electrical Discharge Machining--make money online part 1

today on Applied Science I'm going to

show you how I built this EDM drilling

machine now it's not electronic dance

music that actually electrical discharge

machining and it can do some pretty cool

things one of the key features of the

EDM process is that the drill or the

machining electrode doesn't exert any

pressure on the thing that it's

machining so you can drill into the side

of a round contour and the bit doesn't

stray off like it would with a you know

conventional drill bit also the hardness

of the material is not much of a factor

so you can drill through things like

hardened steel bearings no problem drill

bits even tungsten carbide which is

pretty incredible this process is also

very good for super high aspect ratio

holes and so this is like a point seven

millimeter hole that's about thirty

millimeters deep very high aspect ratio

using a drill bit to do this would be

really difficult in fact I've been able

to drill through every single conductive

material that I've found in the shop so

um someone has a suggestion for

something else to try that's conductive

just let me know you've probably done

some electrical discharge machining and

may not even know it if you've ever used

a benchtop

electrical power supply and brush the

leads together and seen some sparks

coming out you've actually been doing a

little bit of machining on the leads

there and so if we look at the alligator

clip after I've brushed it against the

other terminal a few times you can see

that there's actually little craters

little pits in the alligator clip and

that is the result of EDM so when

there's a spark bridging between the

electrodes the spark is very very hot

hot enough to melt or even vaporize a

teeny tiny bit of the metal and those

little craters are now left there

because the metal has been either melted

or vaporized the reason that your whole

alligator clip doesn't disappear from

you know striking it on the other

terminal like this is that the amount of

material removed is very tiny and once

the spark is extinguished either because

the two pieces of metal are in contact

now then there's no more material

removal so the trick to get EDM an

efficient process if we actually want to

use this to machine something is to

basically turn the spark on and off very

rapidly so that as the nest the bit near

the

thing that's eroding the material moves

in the spark will form blow away a

little bit material but then you want to

extinguish the spark right away and then

turn the power back on so that a spark

forms somewhere else so that these

little craters that material removal

happen very smoothly across the whole

surface so the trick is we need a a high

current power supply at high frequency

like about 30 kilohertz let's say that

has good current regulation and also the

ability to control how long the spark is

on and how long the spark is off and

that's what this is this is the arc

generator on loan to me from Beck's EDM

and as far as I know this is the first

EDM power supply that is intended for

small shops and potentially even

hobbyists so you can build this into

whatever kind of EDM machine you want

today we're going to look at an EDM

drill but another popular one that I'll

probably do a future video on is wire

EDM the next part of the system is the

motion controller which is made by a

company called Dyna motion and there's a

specific reason that you want to use

this particular motion controller in

that it can control the CNC machine in

the forwards and reverse feed rate

direction and this becomes really

important because in the EDM process

occasionally the you let the electrode

will bump into the workpiece and make a

short-circuit and you actually have to

go backwards to clear this short and

start EDM machining again and there's

very very few motion controllers that

allow you to go backwards in your CNC

profile so inside this computer case

I've just bought the Dyna motion boards

and you don't have to put them in a

server rack like this I did this just

cuz it's convenient for the actual CNC

machine itself

I used a kit from open builds this one's

called the Sphinx because it has two

y-axis motors and I can get my tub of

water in the middle there without

interfering with either axis and I've

been kind of curious about this open

build stuff the idea is that the company

sends you a kit of parts including these

aluminum extrusions and the motion

feature the way that they make a slide

out of this is to have plastic sort of

skateboard wheels that ride in a track

on the extrusion and I always was kind

of skeptical about this but actually it

works much better than I would have

guessed also the kit does not have ball

screws but the nut that the driveshaft

runs in is like a Delrin nut and the fit

is very tight so the backlash is very

low I actually measured it myself at

about half a thousand inch in most of

the axes here I used the kit pretty much

as designed and just made a few tweaks

here and there that I thought improved

the performance a little bit we'll talk

about those later the drill head that

I'm using was a bit of a lucky find

initially I thought I was going to have

to build this whole drill head myself

from scratch and so I was designing it

also lucky that the open builds thing is

in fact open source and so I actually

had the CAD for this so I sat down and

started to do the CAD for a custom drill

head and I realized that I was going to

need some custom rubber seals this is

actually what seals the high-pressure

water into the drill which is hollow so

I was searching like Alibaba and eBay

and all that stuff for these rubber

seals and to my surprise I actually

found an entire complete EDM drill head

on Aliexpress for like $60 I couldn't

believe it I mean it was cheaper than

the raw materials we're gonna cost me

from McMaster buy a lot so I bought the

whole drill head is sort of on spec and

it showed up in a week or two and what

do you know it's perfect

so you'd be surprised that there's

actually not that many EDM drill designs

out there in the world and so basically

if you search for EDM EDM drill rubber

seals or whatever they're pretty much

all 9 millimeters in diameter or a lot

of them are and they all are designed

for the same type of spindle and

everything so it's nice that it's rare

enough where they kind of everything is

almost the same because no one's really

bothered to invent multiple versions of

it the water system works like this

there's one pump here and this draws

water out of the tank and forces it

through these two filters that are in

series and these are just standard cheap

water filters that I got off of Amazon

then the clean water comes out here and

goes into a tee and one end of the tee

goes into this airless paint sprayer

which is basically like a high pressure

pump that's lower volume than a pressure

washer but is otherwise fairly similar

and the other end of the tea comes up

here and goes back into the tank

so depending what kind of operation

we're doing we might want relatively low

pressure flushing water just to get all

the debris from the EDM process out or

if we're doing EDM drilling we actually

need a really high pressure source of

water which is why we need that airless

paint sprayer and the reason it needs to

be so high pressure is that if the drill

rod is you know six tenths of a

millimeter in diameter there's actually

a hole going down through the middle of

this and it takes a lot of pressure to

get water to flow through this long of a

rod at once with such a tiny internal

diameter so if you're way down at the

bottom of a high aspect ratio hole you

still need to have good flow in there to

flush out all the chips and so that's

why we need such a crazy high pressure

it ends up being about a thousand psi or

about you know sixty or seventy bar

something like that I should add that in

most professional EDM systems they make

a big deal out of the water filtration

if you are running like high volumes

through all this the amount of debris

that the EDM process causes will quickly

clog up one of these household water

filters and so they make basically EDM

water filters that are much larger and

just have more surface area to catch the

dirt and then also you have to control

the conductivity if the water if you're

really doing this professionally so you

don't want to use absolute pure

distilled water because the conductivity

is too low and you can't use tap water

because the conductivity is too high so

generally what the pros use is an

ion-exchange filter and it measures the

conductivity of the water and then sends

that through this ion exchange filter to

lower the conductivity well I don't have

any of that running basically what I do

is just get a tub of distilled water

from the store and use that and as time

goes on it will get into the right

conductivity range and if you go long

enough it'll probably become too

conductive but it's easier to just throw

the water out I mean water your plants

with it and then dump a new jug of

distilled water in and so far I've been

running this for a couple of weeks and

haven't had any problem so that's that's

been working great

the drill head also rotates just with

this low-power gear motor and so you can

see it kind of spins the drill rod

around and that's not because there's

any sort of cutting tines or anything on

there it doesn't really matter that it's

spinning this just helps keep the system

as consistent as possible

so when drilling through the electrode

actually erodes away not as much as the

workpiece hopefully but it does erode

and if you're spinning around that makes

the erosion much more even so the hole

will come out more concentric and having

this spin also helps with the flushing

process so that there isn't like sort of

a channel I can imagine like erosion on

a hillside you don't want the water to

keep flowing through the same side over

and over so having this spin around just

keeps everything more even this bracket

here is 3d printed I imported the

open-open builds CAD in and put all this

together and then catted it up in fusion

360 and printed this on the form too and

this is in durable resin so I could

actually clamp down on this and it

worked great I actually printed the

threads direct in there so let's set up

for a drill here let's let's cut

something I'm gonna unscrew this so you

can see how it's built and there's a

Jacob's taper number zero which is

actually holding the Chuck to the

spindle so you can see how this is put

together the drill shop really is

clamping down on this so that as it

spins it can positively drive it but the

trick with this whole drill head is that

we want a couple you know thousand psi

water into the into the actual electrode

but we don't want the water of course to

get onto our Chuck or anything else so

what I'm going to do is briefly turn on

the water pump and it's going to force

out the rubber seal that's currently

jammed in there

okay so you saw the the seal fall out

and this is what I was talking about

earlier it has these kind of

weird-looking seals and the trick is it

has to make a good seal with this tiny

electrode or the tiny the drill rod

basically for EDM and so it has this

channel cut in the top so that the

high-pressure water actually causes the

seal to pinch down tighter onto the rod

so when as thing is assembled it looks

kind of like this and that's and this is

where the water stops so the water never

actually gets down to the chuck and then

in the top side there's a rotating

connection which couples the water from

the stationary part to the spindle which

is rotating so inside here there's

obviously a part that's inside bearings

and rotating and it's Hollow and filled

with the high-pressure water okay so to

set this up for a new cut I'm going to

take the old rubber seal off I'm going

to throw that one out although you can

reuse them multiple times and I'm gonna

undo the chuck hopefully I don't like

this Chuck much at all anyway it's it's

open so that's that's how much electrode

is left that we can't really use because

of the geometry of the system so we

throw that one away these are what the

electrodes look like bought new I got

these off of ebay and they are

purpose-built for EDM drills very common

is to using brass electrodes and the

reason for that is that the blend is

copper and zinc that's what brass is and

the copper is good because it has good

electrical conductivity and the zinc is

good because it vaporizes very easily so

as this thing is drilling down into the

material the electrode is being eroded

as well as the workpiece and we don't

want sort of gobs of molten metal

sticking in there it would be much

better if it vaporized and then sort of

made like a smoke almost that the water

carries away so the zinc is better at

being turned into smoke so we'll put the

electrode into the drill chuck

I actually cut these electrodes in half

just because this machine is not quite

tall enough and I'm gonna use a new

rubber seal and it's actually completely

sealed at the top so it actually pierced

through there I'm gonna stick this out

just a little bit more so that the seal

can basically go down to really small

diameter drill rods in fact it's not

uncommon to get down to like 300 micron

that still have a hole down the middle

it's really quite something so that's in

there and then on the bottom side here

this is the electrode interface er that

I came up with myself which I don't know

if this is really pro or not but it's

basically just a piece of brass with a

hole that's very very closely matched to

the electrode diameter and it's sitting

in a 3d printed piece of plastic and

then the thing that is mounted in the

plastic is actually a ceramic bushing

which is purpose-built again for EDM

drills and you'd think all this is like

really specialized hard to get stuff but

actually this also came from ebay in the

same lot where I got these electrodes so

it's easier to find some of this stuff

than you might guess initially I tried

different things to interface the use of

the electrical connection from the art

generator to this electrode and I had

like spring fingers and stuff that were

pinching it but the problem is that if

you apply any force any side force to

this drill rod it causes the thing to be

wonky right like it's if you're going

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