There has been a long-standing, unresolved debate over whether graphite or copper is a better EDM electrode material. The preference is most always the same in any one geographical region. In North America , the preferred electrode material has shifted from copper to graphite. In Europe and Asia, many argue that copper is the preferable material. Perhaps it’s time to take a closer look at both materials to identify the differences and help you select the one that is most appropriate for your EDM applications.
Electrode Material Considerations
Material variety. Graphite is produced with a wide range of material characteristics, enabling you to match the electrode material properties to the EDM application. Less-critical applications with electrode features such as a large radius, an open tolerance or minimal EDM requirements would use an economically-priced graphite material with large particles and lower strengths. However, a highly detailed electrode with critical features, extreme tolerances and stringent EDM requirements would entail a more premium graphite to fit the needs of this application.
On the other hand, due to the high purity value required for efficient EDMing, the types of copper available on the market and used in EDM applications are limited. This minimizes the ability to match material characteristics to the EDM application. The most commonly used types are electrolytic copper and tellurium copper, which vary slightly in elemental composition and are both cast as a solid.
Cost. Copper is often considered a commodity material and can be less costly than graphite in the bulk or blank stage. Many graphite materials are considered specialty materials and, as such, can be more costly. In addition, copper is recyclable whereas graphite is limited in its ability to be reclaimed. However, with the wide range of graphite materials available on the market today, it is possible to find some low-quality EDM grades that are more economical than copper. To establish the true cost of copper versus graphite, the value of machining the electrode must also be considered. Even with the more expensive graphite materials, the machining costs often offset any savings that are realized with the copper.
For example, a quote was recently solicited for a simple electrode blank with a ground finish on the top and bottom. The quote was received with copper at $4.68 per cubic inch, while a premium grade of graphite was quoted at $6.80 per cubic inch, or 45 percent more costly. However, when the cost of machining a simple, finished electrode was included, the story changed. In this case, the finished graphite electrode was quoted at $15.50 each, whereas the copper electrode (“oxygen free”) was quoted as $95 each. Due to the soft, ductile characteristic of copper, it is often gummy, and conventional machining practices (such as feeds and speeds) must be altered to accommodate. This can be mitigated with tellurium copper, but EDM performance may be jeopardized. On the other hand, graphite is not gummy and can be conventionally machined very easily. However, machining graphite generates significant dust, which must be collected through an effective vacuum system with HEPA-type filtration.
Detail. In EDM applications, the electrical current tends to concentrate at sharp edges and corners. Copper’s low melting point does not allow it to handle current density as effectively as graphite, so features on a single copper electrode must be similar in detail. It is not wise to EDM with varying details on the same copper electrode. This is because the higher current required to efficiently EDM larger electrode details exceeds the current allowable for the smaller detail.
With copper electrodes, high current density on smaller, more intricate detail increases the electrode wear. Also, when machining intricate detail or EDMing at high current densities, a copper electrode may move or flex as material stress is relieved. This limits the ability to maintain the very tight tolerances required on many of today’s molds. Graphite performs very well at a high current density even with complex geometry. Graphite electrodes allow for efficient EDMing, even with varying details on the same electrode. Therefore, the number of graphite electrodes required to perform a job can be significantly reduced.
EDM Performance
Metal removal rates. An electrode material’s thermophysical properties determine its ability to process the energy of the EDM cut and remove metal. In generating a spark, peak current is discharged only after the gap between the electrode and workpiece has been ionized. At this point, the electrode emits electrons that collide with the molecules of the dielectric fluid. As a result, the fluid is vaporized and an energy channel is formed that allows the spark to take place. For this to happen, the electrode material must be hot enough for electrons to absorb enough energy to escape and work to create the energy channel.
For copper electrodes to release electrons in the gap, the temperature must be high enough for these electrons to absorb sufficient energy.1 As a result, these high temperatures tend to burn some of the copper electrode away. In order to generate this heat, the on times for copper electrodes are generally much higher than for graphite electrodes. However, due to its carbon base, a graphite electrode is able to emit these electrons at much lower temperatures and does not require the extended on times for electrons to release and create the energy channel. Therefore, the time required to form the energy channel is considerably less. Since the graphite initializes the spark faster, significantly higher metal removal rates are the result.
Wear. Electrode wear is a constant concern because excessive wear results in adding electrodes or redressing electrodes more often. Graphite is able to achieve electrode wear of less than 1 percent in relation to the depth of cut at machine parameters much more aggressive than copper electrodes. This is achieved through a “replating” process during which molten particles from the workpiece may penetrate into the structure of the graphite electrode and reduce the amount of wear caused by the EDM process. The melting temperature of most standard work metals being EDMed is around 1,500°C. This exceeds that of copper, which is around 1,100°C. Any molten particles being ejected out of the EDM cut are likely to carry a thermoelectric charge and have temperatures that do not permit them to affix to the copper electrode. In this case, the molten particles may actually create secondary discharging and erode the copper electrode away.
This means that the high amperage and long on times of a roughing condition (and the process of replating) actually preserve the graphite electrode but is detrimental to the copper electrode which erodes away at these settings. On the contrary, in the finishing stages, with low amperage and short on-times, the graphite electrode has a tendency to wear at a faster rate than copper. However, since electrode wear is a ratio of the amount of material removed in the EDM cut, the actual wear on either a graphite or copper electrode is minimal in the finishing stage and sometimes immeasurable.
Surface finish. Because it is cast as a solid with no porosity, it goes without saying that copper electrodes provide very fine surface finishes. However, with the sophistication of today’s EDM sinker technology, the surface finish gap between graphite and copper has narrowed significantly. Fine-grain graphite electrodes are now able to deliver surface finishes similar to copper with comparable electrode wear. With the proper electrode material selection and machine parameters, graphite is able to achieve near mirror finishes without the use of a powder additive and mirror-like finishes with the additive.
Conducting test burns and tracking results will help determine the monetary impact that the electrode material has on an EDM application. Part 2 of this article will review the results of EDM testing conducted with both graphite and copper, and reveal the bottom-line cost for each. With all of this information, you will then be able make an informed decision on the electrode material type best suited for a specific EDM application.
Graphite is by far the most popular material being used to produce EDM electrodes in the world today. Over 70% of the global market currently uses graphite electrodes for EDM and in the United States it is as high as 95%. With our extensive inventory of graphite materials, we can quickly produce electrodes from any grade required. The advantages of graphite over copper when producing EDM electrodes are many, these advantages include:
Graphite is able to achieve electrode wear of less than 1% in relation to the depth of cut, while working to more aggressive machine parameters. This means, unlike copper, the high amperage and longer on-times actually preserve the graphite electrode.
Fine grain graphite electrodes are able to deliver similar surface finishes to that of copper, while offering much faster speeds and vastly reduced electrode wear.
Graphite is produced with a wide range of material characteristics, enabling you to match the electrode material properties to the EDM application.
Significant cost savings can be made choosing graphite over copper, generated through reduced machining times and speed of cut, less production time to create electrodes, faster EDM times and better throughput from EDM machines.
The electrode material selection process should start with the consideration of five important factors:
Metal Removal Rate. This is the amount of material removed in a given period of time; most commonly measured in cubic millimetres per minute.
Resistance to Wear. This is one of the most important aspects of electrode material selection. There are four types of wear to consider: volumetric, corner, end and side wear, with corner wear usually being the greatest concern.
Surface Finish. The surface finish required can sometimes dictate the selection of the electrode material. For a fine finish using graphite, the electrode material should be dense. Mirror finishes are usually obtained with multiple metal electrodes or graphite electrodes and motion (orbiting or rotation).
Manufacturing Costs. This depends upon the complexity of the electrode. The more complex the electrode is, the higher the manufacturing costs will be
Raw Material Costs. This is usually only a small part of the total EDM time/cost evaluation. Unless it is an unusually large or high volume application, all four of the above points need to considered first before this becomes a major factor.
The next step is to consider some basic facts concerning the nature or properties of the work-piece and the electrode materials.
The approximate melting temperature of the work-piece material should be known. With all of the different alloys in use today, this can prove a difficult task, although material suppliers are a good source of information. Knowledge of the approximate melting temperature alone will usually be enough to start with, but it is also useful to know the material’s specific gravity or, in layman’s terms, its density. Knowing the specific gravity will give a good idea of how many molecules will have to be removed, and if they are big or small in molecular terms.
Electrical discharge machining is more popular than ever and has become an integral component of both the toolroom and the production floor. CNC and improved power supplies resulting in increased metal-removal rates have expanded the applications for EDM in the tool and die shop, as well as in the aerospace, plastic mold, and automotive industries.
And while tool and die work is still the mainstay of EDM, mass production applications, including transfer lines and FMS cells, are often taking advantage of today’s EDM technology. New techniques using multiple electrodes, automatic dressing, and sophisticated holding devices are further enhancing EDM’s burr-free, close-tolerance cutting.
For some shops, the expanded role of EDM introduces new challenges relative to selecting electrode materials. For instance, a carbide specialty shop, that invested in EDM for operating efficiencies will need to explore a wide range of new electrode material possibilities should it begin working in steel or aluminum.
Electrical discharge machining is more popular than ever and has become an integral component of both the toolroom and the production floor. CNC and improved power supplies resulting in increased metal-removal rates have expanded the applications for EDM in the tool and die shop, as well as in the aerospace, plastic mold, and automotive industries.
And while tool and die work is still the mainstay of EDM, mass production applications, including transfer lines and FMS cells, are often taking advantage of today’s EDM technology. New techniques using multiple electrodes, automatic dressing, and sophisticated holding devices are further enhancing EDM’s burr-free, close-tolerance cutting.
For some shops, the expanded role of EDM introduces new challenges relative to selecting electrode materials. For instance, a carbide specialty shop, that invested in EDM for operating efficiencies will need to explore a wide range of new electrode material possibilities should it begin working in steel or aluminum.
In terms of material cost, it is commonly assumed that copper is lower priced than graphite. This is often the result of comparing the price of copper material with more expensive grades of graphite available. Due to the wide range of graphite materials available, it is proven that some EDM grades are more economical than copper. Furthermore, most comparisons do not consider the cost of machining the electrode. Significant cost savings can be made choosing graphite over copper, generated through reduced machining times and speed of cut, less production time to create electrodes, faster EDM times and better throughput from EDM machines. For example, due to the soft ‘ductile’ characteristics of copper, the material is often ‘gummy’ and conventional machining practices, such as feeds and speeds must be altered to successfully machine this material. This results in longer machining times and increased costs. In comparison, graphite can be conventionally machined much more easily and quickly and even with more expensive graphite materials, the machining costs often offset any savings that are realised when choosing copper.
how to choose graphite materials, there are mainly the four indicators that directly determine the performance of the materials:
1. Shore hardness of the material
Graphite is harder than metal materials, and the loss of the cutting tool is greater than that of the cutting metal. At the same time, the high hardness of graphite material in the discharge loss control is better.
2. The inherent resistivity of the material
The discharge rate of graphite material with high inherent resistivity will be slower than that with low resistivity. The higher the inherent resistivity, the smaller the electrode loss, but the higher the inherent resistivity, the stability of the discharge will be affected.
3. The bending strength of the material
The flexural strength of a material is a direct reflection of its strength, indicating the tightness of its internal structure. The material with high strength has relatively good discharge resistance performance. For the electrode with high precision, the material with good strength should be selected as far as possible.
4. Average particle diameter of the material
The average particle diameter of the material directly affects the discharge condition of the material. The smaller the average particle of graphite material is, the more uniform the discharge is, the more stable the discharge condition is, the better the surface quality is, and the less the loss is. The larger the average particle size is, the better removal rate can be obtained in rough machining, but the surface effect of finishing is poor and the electrode loss is large.
At present, there are many different grades of graphite available from graphite electrode suppliers. Generally according to the average particle diameter of graphite materials to be classified, particle diameter ≤ 4 m is defined as fine graphite, particles in 5~ 10 m is defined as medium graphite, particles in 10 m above is defined as coarse graphite. The smaller the particle diameter is, the more expensive the material is, the more suitable graphite material can be selected according to the requirements and cost of EDM.
How to choose the electrode material for “middle-sized or large-sized mold of plastic / die-casting”
(1) Characteristics of the mold
Molds of this field are represented by plastic molds for home electronics and automobiles. A large number of electrodes may be used and it may become around 400 of them for a single mold. In addition, the electrode sizes are widespread from a small one to a large one. Small electrodes are around 70% of the number of electrodes even for a large-sized mold, because it has a lot of small machining areas such as the reinforcement area (rib groove) above all.
Large number of electrodes
Extensive variety of electrode sizes (70% of electrodes are small ones.)
Emphasis on removal rate than the machining accuracy
(2) Elements required for the electrode material
The element made much of is machining efficiency at the time of the electrode production and removal rate at the time of the electric discharge machining. Graphite is used as the electrode material for this reason. Many kinds of graphite for electrodes are widely used. As for the high quality type of small graphite particle size, the finishing quality at the time of EDM is good. On the other hand, machining efficiency at the time of electrode production by milling is extremely bad. For this reason, average quality graphite of relatively large particle size is used for molds of the middle and large size. Also, graphite has an advantageous characteristic of less bending at EDM even for the thin electrode for reinforcement area.
As for a matter that requires attention on choosing graphite, an abnormal electric discharge is easy to be generated at the time of EDM, and when the electric discharge area at the time of starting EDM is small, or when EDM condition of small electrode wear is used, the risk increases in particular. For this reason, in case of using graphite, the EDM condition of a little larger electrode wear is suitable, and it is necessary to deal with it by increasing the number of electrodes for the same machining area.
The graphite has high machining efficiency at the time of the electrode production
As for the graphite, removal rate at the time of EDM is fast
How to choose the electrode material for “small mold of plastic / die-casting”
(1) Characteristics of the mold
Molds of this field are represented by plastic molds for such as cellular phones and digital cameras. In machining of the cavity surface, the surface finish will be required to be high quality of fine surface roughness which is easy to polish. On the other hand, in machining the core side, many small electrodes are necessary though importance of surface quality becomes small
High-quality surface finish cavity
The importance of surface quality of the core is small, but you need a large number of small electrodes
(2) Elements required for the electrode material
The important element is surface quality. For this reason, electrolytic copper is used as the electrode material. In EDM, electrode wear generally increases in the domain of fine surface roughness, but graphite has this tendency extremely much, and high quality graphite of small particle size is used for machining of small surface roughness. Still more electrode number is required than copper. On the other hand, the graphite which is high in machining efficiency at the time of electrode production is suitable for machining of core side because of a large number of electrodes.
Copper is suitable for high-quality machining
Graphite has high machining efficiency at the time of electrode production
How to choose the electrode material for “precision plastic molds”
(1) Characteristic of the mold
Mold of this field is represented by plastic mold for electronic parts and engineering plastics. Dimensional accuracy is required.
Making much of dimensional accuracy
(2) Elements required for the electrode material
The element made much of is machining accuracy. High machining accuracy is required at the time of electrode production and EDM. Generally, copper is used. And also, non-copper materials are used because of their advantages. For example, copper tungsten and graphite are used because of cutting performance at the time of electrode production and because of less thermal expansion at EDM, and graphite is used because of an advantage that an electrode is inflexible by heat at the time of EDM, and so on.
Copper has general appropriateness
Copper tungsten and graphite have an advantage of efficiency of cutting at the electrode production
Copper tungsten and graphite have an advantage with less thermal expansion at EDM
Graphite has an advantage that the electrode is inflexible by heat at EDM
EDM electrode materials need to have properties that easily allow charge and yet resist the erosion that the EDM process encourages and stimulates in the metals it machines. Alloys have properties which provide different advantages based on the needs of the application.
Brass is an alloy of copper and zinc. Brass materials are used to form EDM wire and small tubular electrodes. Brass does not resist wear as well as copper or tungsten, but is much easier to machine and can be die-cast or extruded for specialized applications. EDM wire does not need to provide wear or arc erosion resistance since new wire is fed continuously during the EDM wiring cutting process.
Copper and copper alloys have better EDM wear resistance than brass, but are more difficult to machine than either brass or graphite. It is also more expensive than graphite. Copper is, however, a common base material because it is highly conductive and strong. It is useful in the EDM machining of tungsten carbide, or in applications requiring a fine finish.
Copper tungsten materials are composites of tungsten and copper. They are produced using powder metallurgy processes. Copper tungsten is very expensive compared to other electrode materials, but is useful for making deep slots under poor flushing conditions and in the EDM machining of tungsten carbide. Copper tungsten materials are also used in resistance welding electrodes and some circuit breaker applications.
Graphite provides a cleaning action at low speeds. Carbon graphite was one of the first brush material grades developed and is found in many older motors and generators. It has an amorphous structure.
Molybdenum is used for making EDM wire. It is the wire of choice for small slot work and for applications requiring exceptionally small corner radii. Molybdenum exhibits high tensile strength and good conductivity, making it ideal where small diameter wire is needed for demanding applications.
Silver tungsten material is tungsten carbide particles dispersed in a matrix of silver. Silver offers high electrical conductivity and tungsten provides excellent erosion resistance and good anti-welding characteristics in high-power applications. This composite is thus the perfect choice for EDM electrode applications where maximizing conductivity is crucial.
Tellurium copper is useful in EDM machining applications requiring a fine finish. Tellurium copper has a machinability that is similar to brass and better than pure copper.
When choosing an electrode material, you must consider many factors. The usual first decision is, should you choose a metallic or non-metallic electrode? Depending on the material to be removed, this can be as simple decision. Carbides and sintered metals require more heat, and the highly conductive metallic electrodes will allow for more current to reach the gap—and therefore perform better when machining these types of materials. When machining stainless steels, tool steels and mold steels, non-metallic electrodes such as graphite are a common and very acceptable choice.
First, a few properties of the metallic type. The most common metallic electrode material is copper, and like most metals, there are varying forms of hardness and alloy content. As a high-quality electrolytic, copper makes up a high percentage of metallic electrodes. Some of the requirements needed include free machining, high conductivity, and the ability to machine extremely fine detail without the worry of damage or breakage during the manufacturing process or the setup process. Also, because copper has a tight molecular structure, the ability to produce exceptionally fine finishes is another determining factor in choosing copper. Another commonly overlooked advantage would be the ability to reuse the electrode by re-machining or simply re-purposing the electrode as a completely different-shaped electrode. It should also be noted that it can be machined by the wire EDM process in fine detail and with little or no waste, and therefore has some economic influences in job costing.
Although copper has great potential for almost any application, it is unforgiving if the machining conditions or the flushing conditions are not selected properly. The machining conditions selected will vary from machine manufacturer to machine manufacturer, and in some cases, there may be advantages to certain types of power generation supplies. Copper requires a very stable and high machining temperature in order to control electrodes where ratio and surface finish. One of the most common mistakes with metallic electrodes is to over-flush the gap, causing a cooling effect on the electrode, stopping the re-plating process and causing high wear to the electrode. By simply using a Z-axis pulse or a light flow of dielectric flush through the gap, a copper electrode may experience virtually no wear, which will allow the electrode to be used for many cavities without variation in size or surface finish.
The most common non-metallic electrode material is graphite, and again, there are many variations in the types of graphite available. Most often, graphite will be picked by its grain size and hardness. The hardness will determine the machinability when forming the electrode, and the grain size can determine the finish on the workpiece. Although graphite electrodes are very forgiving when it is over-flushed, it is less forgiving when the power settings are not selected properly; this usually results in a short-circuit or direct current arc, which destroys both the workpiece and the electrode at the point of the short. This is commonly referred to as a “DC arc,” which comes from the visual similarity to a DC welder.
Another common form of electrode material is the combination of copper-infused graphite. Although there are some advantages to this material, if you carefully examine the technologies used in spark conditions and the effect that they have on the metallic versus the non-metallic electrode, you will notice that the current range required to keep the wear at a low and tolerable level when using the graphite electrode is offset by the high wear of copper. This disadvantage is usually offset by the machinability of exceptionally fine detail when manufacturing the electrode in a high-speed machining center. These facts about these two electrode types are supported by the technology that you will find in the machine manufacturers’ technology charts and manuals. Although different manufacturers may have similar work-arounds to utilize a more common electrode material and manufacturing process, the laws of physics dictate whether the electrode will wear or not. We find the technology in spark generation and machine movement has enhanced our ability to control the current flow by detection of abnormal discharges and by controlling the speed of the Z-axis to aid in flushing the gap during the machining process. So, the phrase most used circa 1970 was “there are three problems with EDM: flushing, flushing and flushing. This was one of the operators’ go-to excuses for decades, and now that we understand the electrode response to the material and the control of the spark generation, we now realize that the only issue with EDM is the operators’ understanding and education in Electrical Discharge Machining.
The selection of the most appropriate EDM electrode material is a key decision in the process plan for any job. I will examine the properties of graphite and metallic electrode materials. There are four main properties that effect EDM:
1. Mechanical Properties – The mechanical properties (tensile strength, grain size, hardness) will affect both the fabrication of the electrode as well as the operational performance of the electrode.
2. Structural Integrity – On a microscopic level the EDM process creates very violent sparks. The ability of the electrode material to withstand that stress, will determine the material’s performance regarding surface finish and wear.
3. Melting Point – EDM is a thermal process so the higher the melting point of the electrode material, the better the wear ratio will be between the electrode and work piece.
4. Electrical Conductivity – Since electric current works as a cutting tool, higher conductivity promotes more efficient cutting.
With the increase of the die precision, the quantity of many difficult material parts and the maturation of EDM technology, the EDM electrode of tungsten-copper composite material becomes more and more common. Even so, it is necessary to select the electrode materials reasonably in EDM since it is an important guarantee to ensure the machining quality, while it is also necessary for every technician engaged in EDM to deeply understand the properties of EDM electrode materials.
In a straightforward explanation, the EDM manufacturing process can achieve extremely high precision levels while removing material from substances that conduct electricity. It achieves this goal through the help of an electrode. You can compare how this electrode works to forming shapes out of soft materials. The electrode works by leaving behind a negative stamp on the workpiece you want to machine.
However, the physical process that takes place is indeed a bit more complicated. An electric discharge is let out in the minute gap between the electrode and the workpiece. Such discharges remove the material by melting or vaporizing it. Note that it is necessary for both the workpiece and electrode to remain immersed in a dielectric fluid for the process to function correctly.
The underlying principle which drives machining through electrodes is how you can erode material by exposing it to controlled sparks. During the EDM machining process, no actual physical contact between the electrode and the workpiece takes place. Instead, there a minute gap as thick as a single strand of hair of a human being. Indeed, the amount of material you can remove with a single spark is small and negligible. But the excellent discharge frequency helps to cut down the workpiece relatively quickly. For people fascinated with figures, the discharge takes place several hundreds of thousands of times every second.
One of main reasons people have historically used copper within Electrical Discharge Machining (EDM) is because it is cleaner in their working environment, but is that where the advantages of the material stop?
With over 70% of the global market choosing to use graphite electrode materials over copper today (totalling as high as 95% in the United States), the question is why choose graphite over copper in your EDM applications?
Here, Erodex takes a closer look at the differences between the two materials and outline five reasons why graphite is likely to be the most appropriate for your EDM application needs.
Electrode Cost
In terms of material cost, it is commonly assumed that copper is lower priced than graphite. This is often the result of comparing the price of copper material with more expensive grades of graphite available. Due to the wide range of graphite materials available, it is proven that some EDM grades are more economical than copper. Furthermore, most comparisons do not consider the cost of machining the electrode. Significant cost savings can be made choosing graphite over copper, generated through reduced machining times and speed of cut, less production time to create electrodes, faster EDM times and better throughput from EDM machines. For example, due to the soft ‘ductile’ characteristics of copper, the material is often ‘gummy’ and conventional machining practices, such as feeds and speeds must be altered to successfully machine this material. This results in longer machining times and increased costs. In comparison, graphite can be conventionally machined much more easily and quickly and even with more expensive graphite materials, the machining costs often offset any savings that are realised when choosing copper.
Material Variety
Graphite is produced with a wide range of material characteristics in order to allow matching the electrode material properties to the EDM application. Less critical applications with electrode features containing a large radius, an open tolerance or minimal EDM requirements would use an electrode with large particles, lower strength and economical price. A highly detailed EDM electrode however with critical features, extreme tolerance and stringent EDM requirements would entail a more premium graphite electrode to fit the needs of this application. On the other hand, the types of copper available on the market are few and minimize the ability to match the material characteristics to the EDM application, thus limiting optimum performance.
Electrode Detail
Copper does not have the ability to handle current density as effectively as graphite, which performs exceptionally well at a high current density even with complex geometry, allowing for various intricate machined details to be designed on the same electrode. The result is that the number of electrodes required to perform a job is significantly reduced.
it can carefully select the correct material for a specific job. Graphite can be chosen depending on required surface finish, electrode life, speed of cut or metallurgy of the job. When working with copper however, there is only one form and precisely selecting the optimum material specification is not possible.
EDM Performance
EDM operators know that excessive wear results in the use of extra electrodes or frequent redressing. Graphite is able to achieve electrode wear of less than 1% in relation to the depth of cut, while working to more aggressive machine parameters. This means, unlike copper, the high amperage and longer on-times actually preserve the graphite electrode.
In the aerospace sector when working with very thin, fine detail electrodes, copper is vulnerable to any rough handling and physical damage. Pressure applied to a thin section of copper will cause movement that can go unnoticed, causing further performance issues at a later stage. Graphite on the other hand is either in the right condition, or is clearly broken, vastly reducing the risk of the electrode being used in production.
Surface Finish
Copper electrodes do provide very fine surface finishes. With the sophistication of today’s EDM machine technology, the surface finish gap between graphite and copper has narrowed significantly. For example, fine grain graphite electrodes are able to deliver similar surface finishes to that of copper, while offering much faster speeds and vastly reduced electrode wear.
any material demon-strating good electrical conductivity can be used as EDM electrode. Materials with higher thermal conductivity are suitable as tool electrodes as well as materials with higher melting point and boiling point. Moreover, due to the high pressure and temperature present on the electrode during EDM machining, the electrode material must have accept-able mechanical strength and melting point to reduce tool wear and edge weakness. Furthermore, since the shape of the electrode defines the area in which spark erosion will occur, the dimensional accuracy of the produced part depends on the dimensional accuracy and the surface texture of the electrode.
The two significant factors to consider while choosing your electrode material in terms of both form and function are its resistance to erosion and its high-conductivity. Conductivity is critical. Electric current is the tool used by EDM equipment, and it depends on the cutting efficiency of the electrode significantly. On the other hand, the erosion resistance properties of a material depend on the combination of hardness, melting point, and structural integrity. Materials that resist erosion most have an extended service life. The determining factors that we mentioned, of course, vary from one material to another.
When choosing an electrode material, you must consider many factors. The usual first decision is, should you choose a metallic or non-metallic electrode? Depending on the material to be removed, this can be as simple decision. Carbides and sintered metals require more heat, and the highly conductive metallic electrodes will allow for more current to reach the gap—and therefore perform better when machining these types of materials. When machining stainless steels, tool steels and mold steels, non-metallic electrodes such as graphite are a common and very acceptable choice.
Electrical discharge machining (EDM) makes it possible to work with metal for which traditional machining techniques are ineffective. It only works (except by specific design) with materials that are electrically conductive. Using recurring electric discharge, it is possible to cut small, odd-shaped angles and detailed contours or cavities in hardened steel as well as exotic metals such as titanium and carbide.
EDM electrode materials need to have properties that easily allow charge and yet resist the erosion that the EDM process encourages and stimulates in the metals it machines. Alloys have properties which provide different advantages based on the needs of the application.
Brass is an alloy of copper and zinc. Brass materials are used to form EDM wire and small tubular electrodes. Brass does not resist wear as well as copper or tungsten, but is much easier to machine and can be die-cast or extruded for specialized applications. EDM wire does not need to provide wear or arc erosion resistance since new wire is fed continuously during the EDM wiring cutting process.
Copper and copper alloys have better EDM wear resistance than brass, but are more difficult to machine than either brass or graphite. It is also more expensive than graphite. Copper is, however, a common base material because it is highly conductive and strong. It is useful in the EDM machining of tungsten carbide, or in applications requiring a fine finish.
Copper tungsten materials are composites of tungsten and copper. They are produced using powder metallurgy processes. Copper tungsten is very expensive compared to other electrode materials, but is useful for making deep slots under poor flushing conditions and in the EDM machining of tungsten carbide. Copper tungsten materials are also used in resistance welding electrodes and some circuit breaker applications.
Graphite provides a cleaning action at low speeds. Carbon graphite was one of the first brush material grades developed and is found in many older motors and generators. It has an amorphous structure.
Molybdenum is used for making EDM wire. It is the wire of choice for small slot work and for applications requiring exceptionally small corner radii. Molybdenum exhibits high tensile strength and good conductivity, making it ideal where small diameter wire is needed for demanding applications.
Silver tungsten material is tungsten carbide particles dispersed in a matrix of silver. Silver offers high electrical conductivity and tungsten provides excellent erosion resistance and good anti-welding characteristics in high-power applications. This composite is thus the perfect choice for EDM electrode applications where maximizing conductivity is crucial.
Tellurium copper is useful in EDM machining applications requiring a fine finish. Tellurium copper has a machinability that is similar to brass and better than pure copper.
In EDM, proper selection of electrode materials is an important factor in ensuring processing quality and increasing productivity. At the same time, since the electrodes are processed differently during use, it is difficult to standardize the tool electrodes, and the difference in size or shape is large. Therefore, the following principles should be followed when selecting electrode materials:
1.0 On the basis of analyzing the technical characteristics of the workpiece and the technical requirements (surface roughness, size, tolerance accuracy), the electrode material should be selected according to the workpiece material and technical requirements.
2.0 First consider the choice of materials with good thermal conductivity and high melting point as electrode materials.
3.0 Take into account the factors such as easy electrode forming and good processing performance to obtain good EDM. Although the electrode materials used in EDM are mainly copper, graphite and tungsten-copper electrodes, due to some properties of the high-performance electrode itself such as purity, viscosity, structural compactness, uniformity and physicochemical properties, When it comes to different processing objects and different processing requirements, the selected electrodes and processing parameters are completely different.
Choosing the electrode material depends on the type of mold:
1) How to choose the electrode material for “middle-sized or large-sized mold of plastic / die-casting”
The element made much of is machining efficiency at the time of the electrode production and removal rate at the time of the electric discharge machining. Graphite is used as the electrode material for this reason. Many kinds of graphite for electrodes are widely used. As for the high quality type of small graphite particle size, the finishing quality at the time of EDM is good. On the other hand, machining efficiency at the time of electrode production by milling is extremely bad. For this reason, average quality graphite of relatively large particle size is used for molds of the middle and large size. Also, graphite has an advantageous characteristic of less bending at EDM even for the thin electrode for reinforcement area.
2) How to choose the electrode material for “small mold of plastic / die-casting”
The importance of surface quality of the core is small, but you need a large number of small electrodes
The important element is surface quality. For this reason, electrolytic copper is used as the electrode material. In EDM, electrode wear generally increases in the domain of fine surface roughness, but graphite has this tendency extremely much, and high quality graphite of small particle size is used for machining of small surface roughness. Still more electrode number is required than copper. On the other hand, the graphite which is high in machining efficiency at the time of electrode production is suitable for machining of core side because of a large number of electrodes.
3) How to choose the electrode material for “precision plastic molds”
The element made much of is machining accuracy. High machining accuracy is required at the time of electrode production and EDM. Generally, copper is used. And also, non-copper materials are used because of their advantages. For example, copper tungsten and graphite are used because of cutting performance at the time of electrode production and because of less thermal expansion at EDM, and graphite is used because of an advantage that an electrode is inflexible by heat at the time of EDM, and so on.
The electrode materials for electric discharge machining mainly include graphite, copper and tungsten-copper composite materials. I believe that the master of mechanical machining also knows that in EDM, the physical properties of the electrode material have a great influence on the discharge erosion amount, electrode loss, processing speed, machining accuracy and processing stability. Under different conditions, the use of different electrode materials will directly affect the processing quality.
EDM electrodes consist of highly conductive and/or arc erosion-resistant materials such as graphite or copper. EDM is an acronym for electrical discharge machining, a process that uses a controlled electrical spark to erode metal. EDM electrodes include components made from brass, copper and copper alloys, graphite, molybdenum, silver, and tungsten.
Electrical discharge machining (EDM) makes it possible to work with metal for which traditional machining techniques are ineffective. It only works (except by specific design) with materials that are electrically conductive. Using recurring electric discharge, it is possible to cut small, odd-shaped angles and detailed contours or cavities in hardened steel as well as exotic metals such as titanium and carbide.
People familiar with EDM operations’ workings only know too well that excess wear requires additional electrodes or its only other alternative, i.e., redressing it frequently. Graphite as an electrode material boasts of keeping electrode wear to less than 1% compared to how deep it cuts when used with particularly aggressive parameters. That translates to high ampere levels and greater on-times, which help to preserve the electrode. It is something that copper conspicuously lacks as an electrode material.
We can take the example of EDM use in aerospace, where their thinness and fine details characterize the electrodes. If we use copper in such situations, the applied pressure will result in often unnoticed movements. Copper is relatively fragile and doesn’t tolerate rough handling, and is vulnerable to physical damage. The copper movements resulting from pressure are likely to create significant issues with performance further down the line. EDM Graphite electrode material, in contrast, can easily be identified as being work-ready or being damaged. Such a characteristic dramatically reduces the production risks posed by the electrode.
Please don’t hold the misconception that it is not possible to wire erode Graphite. It is a fallacious view as many leading graphite electrode companies have indeed wire eroded Graphite without breaking it. Even the wire erosion process timings are comparable to that of copper EDM electrodes.
EDM electrodes consist of highly conductive and/or arc erosion-resistant materials such as graphite or copper. EDM is an acronym for electrical discharge machining, a process that uses a controlled electrical spark to erode metal. EDM electrodes include components made from brass, copper and copper alloys, graphite, molybdenum, silver, and tungsten
Electrical discharge machining (EDM) makes it possible to work with metal for which traditional machining techniques are ineffective. It only works (except by specific design) with materials that are electrically conductive. Using recurring electric discharge, it is possible to cut small, odd-shaped angles and detailed contours or cavities in hardened steel as well as exotic metals such as titanium and carbide.
EDM electrode materials need to have properties that easily allow charge and yet resist the erosion that the EDM process encourages and stimulates in the metals it machines. Alloys have properties which provide different advantages based on the needs of the application.
When selecting EDM electrodes, the most important considerations alongside its form and function are the material’s conductivity (or resistivity) and it’s erosion resistance.
Conductivity promotes cutting efficiency, since electric current is the “cutting tool”.
Erosion resistance (a factor of melting point, hardness, and structural integrity) gives the electrode a longer service life and lowers the frequency of replacement. These properties, which vary almost exclusively by the type of alloy or material used, must be the deciding factors when selecting an electrode.
Copper and copper alloys have better EDM wear resistance than brass, but are more difficult to machine than either brass or graphite. It is also more expensive than graphite. Copper is, however, a common base material because it is highly conductive and strong. It is useful in the EDM machining of tungsten carbide, or in applications requiring a fine finish.
Tellurium copper is useful in EDM machining applications requiring a fine finish. Tellurium copper has a machinability that is similar to brass and better than pure copper.
Molybdenum is used for making EDM wire. It is the wire of choice for small slot work and for applications requiring exceptionally small corner radii. Molybdenum exhibits high tensile strength and good conductivity, making it ideal where small diameter wire is needed for demanding applications.
Brass is an alloy of copper and zinc. Brass materials are used to form EDM wire and small tubular electrodes. Brass does not resist wear as well as copper or tungsten, but is much easier to machine and can be die-cast or extruded for specialized applications. EDM wire does not need to provide wear or arc erosion resistance since new wire is fed continuously during the EDM wiring cutting process.
With the increase of the die precision, the quantity of many difficult material parts and the maturation of EDM technology, the EDM electrode of tungsten-copper composite material becomes more and more common. Even so, it is necessary to select the electrode materials reasonably in EDM since it is an important guarantee to ensure the machining quality, while it is also necessary for every technician engaged in EDM to deeply understand the properties of EDM electrode materials.
In EDM, choosing proper electrode materials is an important factor to ensure machining quality and improve productivity. The cavity of the electrode is different in the process of using, so there is a big difference in size or shape and is difficult to standardize the tool electrode. Therefore, the following principles should be followed when selecting electrode materials.
EDM electrode
On the basis of analyzing the characteristics and technical requirements (surface roughness, dimension, tolerance accuracy) of the workpiece, electrode materials should be selected according to the workpiece materials and technical requirements.
Select the material with good thermal conductivity and high melting point as electrode material first.
It takes into account the factors such as easy to shape the electrode and good machining performance so as to obtain a good EDM effect. Although the electrode materials used in EDM are mainly copper, graphite, and tungsten-copper electrodes, however, due to the properties of high-performance electrodes such as purity, viscosity, compact structure, uniformity and physicochemical properties, the selected electrodes, and processing parameters are totally different for different processing objects and requirements.
The element made much of is machining efficiency at the time of the electrode production and removal rate at the time of the electric discharge machining. Graphite is used as the electrode material for this reason. Many kinds of graphite for electrodes are widely used. As for the high quality type of small graphite particle size, the finishing quality at the time of EDM is good. On the other hand, machining efficiency at the time of electrode production by milling is extremely bad. For this reason, average quality graphite of relatively large particle size is used for molds of the middle and large size. Also, graphite has an advantageous characteristic of less bending at EDM even for the thin electrode for reinforcement area.
The important element is surface quality. For this reason, electrolytic copper is used as the electrode material. In EDM, electrode wear generally increases in the domain of fine surface roughness, but graphite has this tendency extremely much, and high quality graphite of small particle size is used for machining of small surface roughness. Still more electrode number is required than copper. On the other hand, the graphite which is high in machining efficiency at the time of electrode production is suitable for machining of core side because of a large number of electrodes.
In EDM, choosing proper electrode materials is an important factor to ensure machining quality and improve productivity. The cavity of the electrode is different in the process of using, so there is a big difference in size or shape and is difficult to standardize the tool electrode. Therefore, the following principles should be followed when selecting electrode materials.
On the basis of analyzing the characteristics and technical requirements (surface roughness, dimension, tolerance accuracy) of the workpiece, electrode materials should be selected according to the workpiece materials and technical requirements.
Select the material with good thermal conductivity and high melting point as electrode material first.
It takes into account the factors such as easy to shape the electrode and good machining performance so as to obtain a good EDM effect. Although the electrode materials used in EDM are mainly copper, graphite, and tungsten-copper electrodes, however, due to the properties of high-performance electrodes such as purity, viscosity, compact structure, uniformity and physicochemical properties, the selected electrodes, and processing parameters are totally different for different processing objects and requirements.
Between copper and graphite I choose electrode material, my first choice is copper.
Ꮋeⅼlo!I always feel that for the electrode copper is better than graphite
Between copper and graphite, I prefer to use graphite as electrode material
Choose graphite or copper, it depends on your EMD
this is an important selection for EDM
We really appreciate your blog！it is very professional and helpful
I think you have really done a good job, this blog is very good!
your suggestion is very good! I got it
We prefer to use graphite as our electrode material.
actually it really depends on your EDM
Fantastic! I appreciate your sharing
if you know your EDM very well, it is easy to do!
Apρreciate your blog. I prefer to use copper as our electrode material
I agree all your opinions in this blog.
maybe you can find these experiences in the instruction book
I prefer to choose copper material as our electrode material
I agree your opinion
Whether graphite or copper, it depends on your EDM
thanks for your suggestion
good experience!
I think this is an issue need to be discussed, maybe the opinion has something different
no matter Graphite or copper you use, actually it depends on your EDM
in our company, we prefer to choose copper as our electrode material.
graphite material is much more expensive than copper
good suggestion!
we prefer to choose graphite as our electrode material
Different stakeholders have different views
good article! thanks for sharing
we prefer to use Graphite material as our electrode material
yes！ it depends on your EDM machine
we prefer to choose copper as our electrode material for our every mold
Actually whether choosing graphite or copper as electrode material, it depends on your product requirement
I think it depends on your EDM
I agree your point!
Graphite and brass are our choice of electrode material
it depends on your EDM, I think your EDM supplier will tell you
this is a good blog, thanks for sharing
that is a good article for me, I got it, thanks!
thank you for your suggestion!
the main electrode material is Graphite and copper， how to choose, maybe ……
your suggestion is very useful for many mold engineers
I think it depends on your EDM:-)
we prefer to choose graphite material as our electrode material
every mold maker knows that very well I think. but still thank you for your sharing
the choice of electrode material is very important
your blog help me a lot on this issue.
good suggestion! we prefer to use copper material as our electrode material
this article is worth reading
This article has a guiding significance,as a mould engineer, I agree your opinion
it depends on your EDM
your analysis is correct!
however, we prefer to use copper material as our electrode material
that is an important suggestion
in my opinion, it depends on your product’s requirement
Our electrode material is copper.
I think your suggestion is very enlightening to us
I think it depends on your product struture.
I learned something useful from this article. thanks!
this article is useful for me
how to choose a suitable electrode material, it depends on your EDM.
I think this is one of the most vital info for me.and i’m glad reading your article.
Graphite and copper are our electrode material
this article helps me a lot, As a fresh mould engineer, I would like to express my gratitude to you, thank you for your sharing
Your opinion is very reasonable
it depends on your EDM, but if it depends on your mold making requirement, maybe you need to buy a new EDM
as a mold engineer, I recommend this blog to our colleagues
actually it depends on your EDM
this article is very good! I accept your suggestion
thanks for your suggestion on this issue
it depends on your EDM and your experience
I think This is a matter of opinion, we can discuss
we prefer to choose copper as our electrode material
we prefer to choose graphite as our electrode material
in my opinion, copper is the best electrode material
we prefer to choose copper as our electrode mateial
We prefer to use graphite as our electrode material
it depends on your EDM. but your suggestion is good
good article! I got it!
Copper and graphite are commonly used to make electrodes
your blog can guide me! thanks!
I think it depends on your EDM.
thanks for sharing your experience on this problem
I think most of mold companies prefer to choose copper as electrode material.
We prefer to use graphite electrodes
Graphite or copper, it depends on your mould manufacturing requirement
We always use graphite material as our electrode material
it is the mainstream to choose copper material as electrode material
it depends on your EDM, in our company,Graphite and copper are our electrode material
our main electrode material is copper material.
We choose graphite material As our main electrode material
The copper material is our first choice
The vast majority of mould companies still prefer to choose copper as their electrode material
Graphite electrode is actually very good for mold manufacturing.
it is an Informative article for a mold engineer, thanks so much!
like most mould companies, we also choose copper as electrode material
Many mould companies in UK still prefer to use copper material as electrode material
our company is more willing to use copper as electrode materials, Due to the good processing property of copper
I find many companies here choose copper as electrode material, I’m glad to tell you the graphite is our main electrode material
Different electrode material requires differnet processing equipment.
Our company also chooses copper material as electrode material
the copper material is our electrode material, maybe it is because of our EDM machine
this article is very useful, it answers all my questions in this issue
Actually Whether choose copper or graphite material,, it mainly depends on your request
I prefer to use copper as the electrode materials, because it is easy to be processed
in my opinion, when you choose graphite as electrode material the quality of the graphite is very important
Choosing the right brass for your electrode is very important
mainly The electrode material of our company is copper, graphite is seldom used
Even if the same copper or graphite materials, their quality is still different. that is very important
Actually the graphite quality from different supplier is difference
Hello my friend! in my opinion, it depends on your EDM machine
Currently copper is our electrode material at our mold workshop, maybe I need to discuss Graphite materials with our mold engineer
I think the mould steel you choose is also an important factor
Excellent beat ! to tell the true, Even if you choose the right material, the quality of the copper and graphite is also very important
This post is very useful for me. I got it, thanks
this article really benefit me, I will recommend to my colleagues, thanks again
at present, the major materials for electrode are copper and graphite, so how to choose, it depends on your EDM machine
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