@@DragonflyEngineeringWow, I didn't know EDM could rough out material that quickly. Thanks for the info. Has your customer considered a heavier texture to hide the sink marks?
I don't know anything about EDM. With this slow removal rate, would it be advantageous to rough the rib slots with a slitting saw on the mill and then use the EDM to finish them?
Yes in most cases it is best to rough with an endmill then burn in the finish only. In this case a mill tool wouldnt cut away enough to justify the work, So I just let it run all day and do other work
![DDG & G Herbo - Nosey [Official Video]](http://i.ytimg.com/vi/I9Ra0Zc2NlQ/mqdefault.jpg)
Very cool, thanks for sharing. Any idea how much material depth is removed per plunge?
It is 50 microns for a rough cutting spark and 2 um for the finish, but the sparks are randomly placed per plunge, think sandblast ing
@@DragonflyEngineeringWow, I didn't know EDM could rough out material that quickly. Thanks for the info. Has your customer considered a heavier texture to hide the sink marks?
I don't know anything about EDM. With this slow removal rate, would it be advantageous to rough the rib slots with a slitting saw on the mill and then use the EDM to finish them?
Yes in most cases it is best to rough with an endmill then burn in the finish only. In this case a mill tool wouldnt cut away enough to justify the work, So I just let it run all day and do other work
Do you use any simulation software for mold flow or shrinkage?
No, usually customers dont want to pay for that. I find it is about as easy to mod an aluminum mold than pay for the simulation software
Solidworks and Inventor have mold simulation software built in.
There's a large market willing to pay for Alps keyboard switch replicas and keycaps and you're making silly toys for no money.