CNC+EDM Processing Case Study

 Job Specification:

                          Material: Aluminum 6061-T6

                          Processes Involved: 3-Axis CNC Machining, EDM

                                Split or Not: No

                                Finishing: Sandblasting, Clear Anodizing

                                Quantity: 2Pcs

                                Lead Time: 4 Working Days

                                Tolerance Requirement: ± 0.005’’ 

         How The Parts Were Made:

          Our engineers completed a design for manufacturing review once they received the product design. Then they made a clear process flow according to the part structure.

     The main process used to make the aluminum parts was CNC machining. This part has multiple faces with rounded edges that make it difficult to hold properly when drilling out the holes. So we created a special fixture to hold this part securely to maintain the right dimensions.      

      In addition, there were deep grooves in the part. Then we chose EDM to cut metal with an electrical charge and it does so quickly and with high fidelity, but the electrode itself is consumed in the process and so is considered sacrificial. We made ten electrodes to form the two cavities. After EDM process, extra CNC Machining was needed to process details.

      After milling, we placed the parts in a sandblasting chamber and applied 100# bead on it to remove machine marks and scratches, which gave the parts a uniform matte finish and removes any burrs.

      Sandblasting provided the ideal surface texture for accepting the anodizing process. We did clear anodizing to get the natural color and to increase corrosion and scratch resistance as well.