Titivating a Wire EDM Machine

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awemawson:
The other metal bits were less of a concern. Amazingly some of the screws actually unscrewed, however several had lost too much material from their heads in the hex socket and had to be carefully drilled out

awemawson:
The part that holds the bearing for the lower wire pulley will need re-making as it is going to have to hold the new contact electrode as well as the pulley - this is it:

awemawson:
I seem to remember that I had to replace that shaft that sticks out of it when I re-did the bearings when I got the machine in the first place.

Now to try and remember how they all fit back together :scratch:

awemawson:
A little bit of progress today - mainly taking decisions as to which way to jump.

It would have been much easier to mount the new Tungsten Carbide contact to the outer side of the wire (ie lhs looking at it), this way I could re-use the existing pulley mounting. However it would be in the way when re-threading the wire and make an already tediously hard job harder.

So I decided to let the wire touch the contact tangentially, and wrap it round the contact by taking the pulley nearer to the machine body - ie to the right as you look at it. However this meant slightly modifying the arm to make room for the pulley

awemawson:
It was a bit like cutting hard swiss cheese - all very porous.

In the picture below, the two white nylon bars represent where I will mount a delrin insulator onto which the contact will mount using a stainless steel stubby axle. The end of this axle will take the power connection.

Slab of delrin, and a bit of stainless bar to re-make a longer pulley mount are on order, along with numerous stainless cap screws

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