Development, analysis and application of surface-oxidized tool electrodes for optimization of electro-discharge drilling – OXI4EDM

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The medium-sized mold and tool making industry, as one of the most important branches in Germany, is confronted with new challenges in global markets due to political and economic developments. In order to ensure competitiveness, the German mold and tool making industry has to maintain its superior quality and productivity by using innovative production technologies.Electro-discharge drilling (EDD) is used for mold and tool making because it’s possible to machine any electrically conductive material, regardless of hardness and strength. The process-related flushing of debris across the side gap leads to negative process impairments due to short circuits and secondary discharges. The aim of the project is therefore the optimization of EDD by the development, analysis and use of innovative surface-oxidized tool electrodes made of copper and brass. By means of the oxidation of the electrode surfaces, the tool lateral surfaces are almost electrically insulated in a previously unreacted manner in order to minimize the shorts and side discharges occurring in the side gap. Based on the knowledge gained in the research project it will be possible to produce drill holes with a greatly reduced process time, with a high aspect ratio, and improved quality (for instance reduced conicity).