Common Misconceptions About Mirror Spark Machine Discharge-SPRT

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Common Misconceptions About Mirror Spark Machine Discharge

2025-08-04

　　Some Requirements for Electrodes in Mirror EDM Processing

　　The electrode materials used for mirror EDM processing are generally copper or tellurium copper, with tellurium copper having lower electrode wear. The selected copper material must be uniform in texture and contain few impurities. Poor quality copper can easily cause excessive electrode wear and surface wrinkling during mirror processing, which must be taken seriously. Although copper alloy electrodes can achieve very low electrode wear, the mirror finish effect is not ideal.

　　Electrodes used for mirror EDM processing must be finely polished and free of tool marks and defects; otherwise, these defects will be replicated on the machined surface of the workpiece. However, the electrode surface itself is not required to meet mirror finish standards.

　　Generally, the size scaling amount for mirror processing electrodes is taken as 0.2 to 0.05 mm on one side. For finishing electrodes, it is usually 0.1 mm per side. When the machining area is small, a smaller value can be chosen; when high profiling accuracy is required, a smaller value can also be selected; for powder-mixed processing, a slightly larger value is appropriate. If the electrode size scaling amount is too small, the machining speed will be greatly reduced.

　　Precision mirror EDM processing requires the use of multiple electrodes. This demands good consistency among the electrodes, high manufacturing accuracy, and high repeatability in clamping and positioning when changing electrodes. Generally, advanced processes such as high-speed milling for electrode manufacturing, positioning methods using reference spheres, and quick clamping positioning systems for repeatable positioning are employed to meet these requirements.

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