How to improve the machining accuracy of Sardick spark machines?

Here are some ways to improve the machining accuracy of Sardick spark machines:

### Electrode selection and preparation
- **Selected electrode materials**: according to the processing requirements to select the appropriate electrode materials, such as copper electrode conductivity is good but relatively large loss, graphite electrode loss is small but the processing surface quality may be slightly poor, tungsten-copper and silver-tungsten alloy composite materials such as better overall performance, according to the specific processing object and precision requirements of the trade-offs between the choice.
- **Ensure the precision of electrode**: the manufacturing precision of electrode should be higher than the precision of the workpiece, the manufacturing tolerance is usually taken as about 1/2 of the tolerance of the workpiece, including the dimensional accuracy, shape accuracy and surface roughness, etc., should be strictly controlled.
- Optimization of electrode design**: When designing the electrode, factors such as discharge gap, chip removal and heat dissipation should be taken into consideration. Reasonable electrode shape and structure can help to improve machining accuracy and stability, for example, multi-electrode machining and electrode flattening can be used to improve machining effect.

### Optimization of machining parameters
- **Precise control of pulse parameters**: Reasonable selection of pulse parameters such as pulse width and peak current. Generally speaking, reducing pulse width and peak current can reduce surface roughness and improve machining accuracy, but it will reduce machining speed accordingly, so it is necessary to find a balance between accuracy and efficiency according to the specific machining requirements.
- **Stable discharge gap**: maintain the stability of the discharge gap is critical to the processing accuracy, can be achieved by adjusting the electrical parameters of the pulse power supply, optimize the servo control system, etc., at the same time to pay attention to the secondary discharge caused by the corrosion products on the impact of the discharge gap, and clean up the corrosion products in a timely manner.
- **Reasonable setting of servo reference**: According to the electrode material, workpiece material, processing depth and other factors, reasonable setting of servo reference to ensure that the electrode and the workpiece between the discharge state is stable, to avoid the decline in machining accuracy due to improper setting of servo reference.

### Management of working fluid
- **Select suitable working fluid**: Different working fluids have different insulation, cooling and chip removal properties, and suitable working fluids should be selected according to the machining requirements and electrode materials, e.g., in finishing machining, working fluids with lower viscosity and good insulation properties can be selected to obtain better machining surface quality.
- **Keep the working fluid clean**: Replace the working fluid and the filter paper core regularly to prevent the impurities in the working fluid and the products of galvanic corrosion from affecting the machining accuracy, and it is generally recommended to replace the filter paper core when the pressure indication is less than 0.18Mpa.
- Optimize the flushing method of the working fluid**: According to the shape and requirements of processing, choose the appropriate flushing method, such as side flushing, bottom flushing or circular flushing, etc., to ensure that the products of galvanic corrosion can be discharged in time, and the temperature of the processing area is uniformly distributed, so as to avoid the machining accuracy problems caused by uneven flushing.

### Workpiece clamping and positioning
- **Ensure clamping accuracy**: Use high-precision fixtures and clamping methods to ensure that the workpiece will not be displaced and vibration in the process of machining, and the clamping force should be moderate to ensure that the workpiece is firmly fixed, but not to deform the workpiece, which will affect the machining accuracy.
- **Precise positioning methods**: the use of appropriate positioning reference and positioning tools, such as edge finder, tool setting instrument, etc., to improve the positioning accuracy of the workpiece, positioning error should be controlled within the allowable range to ensure the consistency and accuracy of the machining dimensions.

### Maintenance and upkeep of machine tools
- ** Regularly check the precision of the machine tool **: Regularly check and adjust the precision of the key components of the Shadick spark machine such as the guide rail of each axis, ball screw, etc. to ensure that the machine tool's coordinate axis movement accuracy, table flatness, spindle verticality and other indicators meet the requirements, generally recommended every three months for the machine tool guide rail ball screw lubricant injection.
- ** Keep the machine clean and stable environment **: Keep the machine body and table clean to prevent oil, chips and other debris into the machining area, affecting the machining accuracy, and at the same time pay attention to the processing environment of the temperature and humidity control, to avoid the temperature difference is too large to cause deformation of the machine tool, affecting the machining accuracy.
- **Timely maintenance and replacement of components**: found that the machine parts are worn or damaged, should be timely maintenance or replacement, such as electrode chuck, wire and other parts of the damage will affect the transmission of discharge energy and machining accuracy, must be dealt with in a timely manner.