How to properly control the machining allowance in mirror EDM processing-SPRT

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How to properly control the machining allowance in mirror EDM processing

2025-08-04

　　The process of electrical discharge machining is a machining process that goes from rough machining to finish machining. First, a rough machining electrode is used to remove a large amount of metal with relatively high discharge energy under the condition of ensuring certain machining quality (dimensional accuracy, shape accuracy, positional accuracy, surface roughness), in order to shorten machining time and improve machining efficiency; then the finish machining electrode is replaced, using lower discharge energy to complete the finish machining. Whether rough or finish machining, multiple discharge conditions are used, with current decreasing from high to low, finishing the bottom by deep feed and finishing the sides by linear movement.

　　Each discharge condition must reserve machining allowance for the subsequent conditions. A reasonable machining allowance is key to ensuring machining quality and efficiency. A larger machining allowance can guarantee surface quality but reduces machining speed. A smaller machining allowance can achieve high efficiency, but the final mirror surface will have many pinholes or unevenness.

　　The ideal machining condition is that after the first condition is completed, the subsequent machining only smooths the surface unevenness formed by the first machining condition without removing new material, treating the material allowance of each condition as zero. However, in mirror electrical discharge machining, considering the various constraints on discharge conditions, it is safer to leave a slightly larger machining allowance.

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