Drill through anything (conductive) with Electrical Discharge Machining--make money online part 2

applying force to it you will have

concentricity problems so I eventually

settled on a bushing which is perfectly

concentric with the axis of this whole

thing and it's conductive so you know

even though there isn't like spring

tension holding it on there I haven't

had a problem with with a loss of

conductivity so what we'll do is thread

this through and the fit is tight enough

where if there's even like a tiny burr

on the end of this drill rod which there

is I can feel it won't go through so let

me clip the end of this I'm basically

just going to cut a very slight taper on

there

and hopefully that'll help us thread

through okay let's see if we can thread

this through there we go so now it's

threaded through the brass through the

ceramic bushing and then I'm gonna head

back up into the spindle here and

tighten this down and this is not a it's

not like it's tightening down to

whatever I feel is tight it actually

goes into a hard stop

so once I've tightened that down it's

it's basically bottomed out and that's

it and now the machine is pretty much

set up so let's drill something the

cutting force is very close to 0 because

the electrode actually never touches the

workpiece it's only the electrical arcs

that jump between them ideally but

remember since we are blowing water

through here at such high pressure there

will be a little bit of force

however the clamping requirements are

basically nothing because there is so

little force here and I have one lead

connecting through the water just

alligator clipped on and four small

holes and stuff like this the electrical

connection is really not that critical

okay so what I'm going to do is jog down

so that the electrode is just about to

punch through and then we'll turn the

water on and drill a hole the software

that comes with the Dyna motion

controller is really deep and

full-featured you can program it to do

almost anything you want and you can

also program C programs and FPGA code

that gets downloaded into the controller

so you can literally create anything you

want the downside of this is that the

learning curve is really brutal luckily

mike backs the creator of this arc

generator has written his own c program

that will control this controller as if

it were a purpose-built EDM machine and

sort of the main thing here is that when

there's a short-circuit or when the arc

length is getting very short like it was

about to be a short-circuit it tells the

controller to back off the feed rate and

I mentioned that most controllers can do

this right like imagine you're running a

milling machine you have a knob where

you can turn the feed rate from a

hundred percent down to zero percent or

two hundred percent or whatever you want

but the trick is almost no controllers

have negative percent feed rate it's

almost unheard of it wouldn't make any

sense for a milling machine

but for EDM like I mentioned if there's

a short-circuit you actually have to

back up to clear that short and this

happens you know occasionally like once

every minute or once every 10 seconds

depending what you're doing and the K

motion controller does this by a analog

link that goes from the art generator

back to the motion controller so there's

basically just a voltage that tells it

how long the arc length is and when it

gets too short or even if it's zero then

it tells the machine to back up and so

all that's been programmed in and you

can just download it and set and get it

going although there's still quite a bit

of setup so we have controls over this

and we can turn the arc on and off and

run G code just like normal and in this

case I'm just going to type the G

commands in we can jog the machine like

this okay so I'm going to turn the water

pumps on the main pump turn on the

rotating spindle and I'm going to turn

the high-pressure pump on so now we've

got about a thousand psi and there's

water flowing through the electrode and

you'll notice that the spindle actually

goes a little bit slower when the

pressure is on it of course because that

rotating seal has all the force on it

now and you'll hear the pump turn on and

off this is how airless paint sprayers

work it actually has a pressure switch

inside there and when it senses the

pressure is too low it just runs long

enough to get the pressure back up so

that's totally normal okay so I'm going

to run the code that initializes the

machine and then sets the feed rate

based on the arc length and I'm going to

drill straight down

I forgot to add that the art generator

can be programmed with different

currents and on times and off times like

I mentioned that this is an important

part of getting a good cut going so when

I started that cut that power was way

too low

so I'm gonna turn this up to about 15

amps just kind of mid scale and put both

of these at about mid scale so arc on

time is like 15 microseconds off time 36

microseconds and that gives us a

frequency of close to 20 kilohertz so

when I say send config all this is

downloaded to the arc generator and now

when we go back to the screen here I'm

gonna run that jeet kune around the

g-code and it's going to use the new

settings basically I mentioned that the

arc length is reported from the arc

generator to the motion controller via

this analog voltage and so the voltage

corresponds to the arc length when it

gets too low that's when we go into this

reverse feed rate control so you can see

in some of the other cuts that I've made

the machine doesn't just plow forward it

actually can sense what's happening

which is a critical part of this whole

EDM so let's go back to the workpiece

and I'll hit start you can see it in

action

and it will pick up speed as it notices

that the arc is stable you can see some

gas bubbles coming out there here's a

shot from an earlier setup just so you

can kind of see what it looks like in

profile cutting speed can be pretty high

especially in aluminum like this I

haven't tried to find the limits but it

can easily cut it maybe oh I don't know

I've seen it go as fast as maybe about a

millimeter per second at this certain

setup so the electrode is all the way

through and as it goes through it's

making the hole slightly bigger because

of you know lack of concentrated either'

[Music]

so as you can see I wasn't really paying

attention there and the electrode it

must have been bent or something because

the hole that it created is much larger

than the electrode itself and that will

happen if there's a bend in it because

we're spinning around nice and

consistently the hole will always be

round but it might be a slightly larger

diameter than the electrode in this case

since the thing was been - there was

something out of a lie

the whole is quite a bit larger however

you might be thinking I wait a minute

this is useful if you chuck up a big

solid piece of brass like a quarter inch

you could actually pretend like it's an

end mill and that is in fact a thing

that we'll look at in a future video

EDM milling which can be really useful

because your mill can be square if you

aren't rotating it you can have a sharp

edged thing and drive it into the corner

of a box to get like a sharp internal

edge and this is pretty common in sinker

EDM which is yet another kind of EDM

process one thing that you have to watch

out for is electromagnetic interference

the EDM process is inherently very

electrically noisy like you've probably

heard of spark-gap transmitters well

this is one heck of a spark-gap

transmitter it's got you know 15 amps

going at and 30 kilohertz might be the

switch frequency but the actual

frequency content of the waveform is

probably much higher than that and that

will in fact cause interference with

electronics and the dinah motion motion

controller boards appear to me to be

slightly more susceptible to EMI then

sort of standard electronics I mean

these are sort of custom-built Fords and

so you have to be really careful and put

ferrite beads on everything and ferrite

toroid 's and make sure it's grounded

and shielded and everything but what you

see here is I would say medium effort I

haven't gone completely nuts and ended

up not having any problems so let's open

up that electrical or let's open up the

computer case there and I'll show you

the Dyna motion boards okay so here

we've got a 24 volt power supply that

runs the stepper motors and the power

supply goes into this stepper motor

driver board and the stepper motors are

connected through a db25 connector that

comes off of here so this is actually

the stepper motor controller that's also

produced by Dyna motion and the stepper

motor is driven through this cat5 cable

this is like Stefan direction signals

that come out of here and this converts

it into the stepper motor actual drive

current the actual Dyna motion

controller is this board here and it's

piggybacked on to an analog input board

which is used for a few things but

mainly it's that feed rate override

control that I was mentioning so this is

the actual 10 volt signal that describes

how fast the machine should be going and

if that signal is too low let's say 2

volts or whatever it actually goes into

reverse feed rate so a pretty standard

stuff I just got a 5 volt supply over

here just to run the logic and there's a

couple of auxiliary ins and outs to

control things like water pumps and that

sort of stuff but I haven't really

hooked any of that up just yet ok like

you say I'm probably going to do another

video on wire EDM which is kind of like

the complement to this if you use hole

drilling EDM to make a hole in something

you can then feed a wire through and

then move the wire around to cut like a

complex 2d shape out or even 3d okay

hope you found that interesting see you

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