Diffuser Shape Technology – Diffused holes created with our patented two-step process. First the cooling holes are drilled; then the diffuser electrode is shaped using a built in electrode dresser programmed to generate the correctly sized diffuser dimension on the electrode. The machine then retraces the initial hole installation path to install each diffuser in the correct location. The “Z” axis actually uses an encoded servo to deliver the 6th axis that is required to position the diffuser in the correct attitude relative to the surface of the part. This process is exclusive to FH Series and Fanuc Control.

This technology is being used for both large Power Generation and small Aerospace parts at companies such as GE, Mitsubishi and Pratt & Whitney. With our Two-Step process, we have been successful at creating multiple types of diffuser shapes at different sizes. These shapes have included, but are not limited too diamond, wedge and conical shapes. Since it is not necessary to remove the part from the machine or fixture and the diffuser shapes are created on the same drilling head assembly used to make the cooling holes, the dependability, speed and accuracy are unmatched by any other process available. 

Shaped Brass Rod

Shapes EDMed in Test material

Here is a link to a video of this process.

http://www.youtube.com/watch?v=z2SauAlwgDE&list=UU6ELCSNNebmtz9PqVrqvllg&index=6&feature=plcp

In what time frame are you planning on purchasing a machine? When does this machine need to be in operation?

 Is this equipment for a specific industry? For example, land base power generation, Aerospace and/or Semiconductor.

 Are the parts Conductive? Can an Electrical Discharge Machine be used to create the part features?

 Is there a nonconductive coating over the parts?

 How many axis will you need? Our machines are usually built with 3 to 7 axis.

 Are there specific Part(s), Job(s) that this equipment will be designated? For example, blades, vanes, rings and/or transition ducts?

 What is the work envelope of the part? For example, 4 inch cube or 5 feet cube.

 What is the material composition of the part? For example, single crystal (inconnel) Stainless steel and/or Aluminum.

 What is the minimum inside diameter holes needed to be EDM drilled?

 What is the maximum inside diameter holes needed to be EDM drilled?

 What is the average inside diameter of the hole(s)?

 What is the minimum depth of hole(s) in the part?

 What is the maximum depth of hole(s) in the part?

 What is the average depth of hole(s) in the part?

 Are there any shaped holes? Diffusers or slot shapes.

 Are there EDM hole quality specifications that are required? Micro-cracking, Recast Layer.

 Are there specific safety specifications and/or standards for the machine that are needed in your facility? For example, Enclosures, stack lights (specifications) CE, Osha and/or NFPA (standards).

 Is there any space limitation at your facility for the machine?

 Is there any weight limitation at your facility?

 Will we be turnkeying a part for you? (Many of our customers will want us to design and program their first part for them, so when the machine arrives it will be immediately producing parts.)

 Does your facility have any EDM experience? For example, wire, conventional and/or Fasthole.

 Does your facility have any 5 Axis CNC programming experience?

 If any, what CAD software do you use at your facility? For example, Unigraphics, Solid Works and/or Master Cam.

In the last 2 months, we have received more calls than ever from other manufacturers that either use Integrity EDM’s services or have lost work to Integrity EDM. Integrity EDM definitely understands EDM.

This goes to show, that if you combine the right tool man and tool, you will get a successful result. I just wish Don wouldn’t pull our logos off the machines.

Here is a link to an article related to Beaumont Machine and Integrity EDM.

http://findarticles.com/p/articles/mi_hb4320/is_5_37/ai_n28999439/

Picture (small) of the Beaumont EDM’s at Intgrity EDM’s facility.

http://www.integrityedm.com/equipment.asp

If you need EDM work done, here are a few of our customers located in North America:

Integrity EDM 12 machines

Turbo Combustion Technologies Cincinnati 8 machines

General Electric 1 machine

Unison Engine Components Wilkes Barre 1 machines

Unison Engine Components Orillia 3 machines

Pratt & Whitney Hartford 4 machines

Mitsubishi Power Systems 9 machines

Honeywell 1 machine

Williams International 1 machine

Acucut 2 machines

LAI International 6 machines

Moeller Aerospace 1 machine

Johnson Technology 1 machine

Power Systems Manufacturing 1 machine

Atlantic Precision Incorporated 1 machine

Aerospace Techniques 1 machine

ProEnergy 1 machine

Sulzer Hickham 2 machines

Reliable EDM 1 machine

ACT Texas 1 machine

Silfex / Lam Research 8 machines

Aero Foil International 2 machines

Walker Forge 1 machine

CTM Corporation 1 machine

Design West Tech 1 machine

Gala Industries 1 machine                             

We also have machines located in France, Poland and Budapest.

So what is copy exact? Copy exact is a commitment to abide by a Process Control Plan without deviation. If changes are necessary, those changes must be communicated to the customer via the Deviation Authorization process prior to submission.” Copy exact is an extension of the Production Part Approval Process:
The Production Part Approval Process (PPAP) outlines the methods used for approval of production and service commodities, including bulk materials, up to and including part submission warrant in the Advanced Quality Planning process. The purpose of the PPAP process is to ensure that suppliers of components comply with the design specification and can run consistently without affecting the customer line and improving the quality systems. PPAP ensures that you will achieve the first time quality and will lower down the cost of quality.

All this really asks of a supplier is “We have approved purchase of your product based on certain assumptions about how you will manufacture, inspect, and ship this product. If anything about the process is going to change, we want to know and we want assurance the change will not affect the product we receive. If you want to be a great supplier and introduce improvements to your process, that’s fine, but be proactive and tell us what you intend to do.”

By understanding and abiding by these processes, Beaumont Machine is continually making progress and increasing its contribution through innovative technology in the Semiconductor industry as well as the Aerospace and Land base power generation industries.

Chris

Here’s a quick and easy guide for determining what type of multichannel electrode you may need. One thing to keep in mind is that not everyone uses the same lingo to describe the same options, but at least this will help get you familiar with what’s available. This is by no means the defining list out there, so if you know of different options or these same options by a different name, let me know.

Thanks,
Vincent Lucas
Consumables Mgr.
vince@beaumontmachine.com

We will be adding something new every month that we have done or are planning on doing. Please check back soon!