**1. Introduction** Electrical Discharge Machining (EDM) is a crucial process in mold manufacturing, especially for injection molds. Despite its importance, many mold companies still face challenges due to imperfect processes, which often result in EDM parts failing to meet the required precision and efficiency standards. This article provides an in-depth analysis of common misconceptions that occur during EDM operations in die and mold manufacturing. **2. Common Misunderstandings in EDM** **2.1 Misunderstanding of Positioning Methods** Accurate positioning is vital for achieving high-quality EDM results. In traditional Z-axis machining, X and Y axes define the cavity position, while the Z-axis controls the depth. One commonly used method involves direct contact between the electrode and workpiece (Figure 1), which is simple and widely adopted by operators. However, this approach has limitations when high precision is required, such as in the processing of plastic molds where tight tolerances are essential. The contact area can introduce errors due to surface imperfections, debris, or misalignment, making it difficult to maintain consistent accuracy below 0.01mm. To address this, indirect positioning using reference balls (Figure 2) is recommended for complex or high-precision tasks. This method reduces errors by using point contact, ensuring better stability and accuracy. While direct methods are suitable for general applications, reference ball positioning offers significant advantages in terms of speed, consistency, and ease of use, especially when multiple parts or electrodes are involved. **2.2 Misunderstanding of Electrode Material Selection** Choosing the right electrode material plays a critical role in the success of EDM. Materials like copper, graphite, and copper-tungsten alloys each have their own strengths and limitations. Many mold companies tend to use the same material for all electrodes, which may seem cost-effective but can lead to inefficiencies and poor performance in certain scenarios. For example, using copper for high-precision machining can cause excessive wear on the machine and require more frequent electrode replacements. Copper is ideal for stable, low-loss finishing, while graphite excels in high-speed roughing and large-area machining. Copper-tungsten alloys are best suited for specialized, high-precision applications where minimal electrode wear is essential. Understanding the specific requirements of each job and selecting the appropriate material can significantly improve both the quality and efficiency of the EDM process. **2.3 Mistakes in Electrode Scaling** Proper electrode scaling is essential for achieving accurate dimensions and surface finish. Many companies rely on fixed scaling values, which may not be suitable for all situations. For instance, using a uniform scale of 0.2 mm for roughing and 0.07 mm for finishing might limit the ability to use larger discharge parameters, reducing efficiency. The correct scaling depends on factors such as the type of machining (translational or non-translational), the size of the electrode, and the desired surface finish. Translational processing allows for greater flexibility and control, particularly in fine finishing. Adjusting the scaling based on the specific application ensures better results and avoids issues like uneven surface roughness or excessive electrode wear. **2.4 Mistakes in Process Methods** Many mold companies still rely on traditional EDM machines, even though modern CNC EDM machines offer advanced capabilities like horizontal and multi-axis machining. These features can greatly enhance productivity and precision, but they are often underutilized due to a lack of understanding. For example, using Z-axis servo feeding for deep, narrow cavities can lead to unstable discharges and slow progress. By contrast, employing horizontal or diagonal machining techniques can improve efficiency and reduce electrode wear. Companies that fail to adapt to these new technologies risk falling behind in an increasingly competitive industry. **3. Conclusion** In today’s rapidly evolving mold manufacturing landscape, staying ahead requires continuous learning and adaptation. Many mold companies still struggle with outdated methods and a lack of awareness about modern technologies. By addressing common misunderstandings in EDM—such as positioning, electrode selection, scaling, and process optimization—companies can significantly improve their overall performance. Advancements like high-efficiency CNC EDM machines, rapid clamping systems, and mixed powder processing have opened up new possibilities for precision and speed. To remain competitive, mold manufacturers must tailor their processes to their specific needs and continuously refine their techniques. With the right knowledge and tools, companies can achieve higher quality, faster production, and greater profitability in the long run.

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