EDM stands for Evil Demon Magic

During my materials research time, I had the opportunity to work on the EDM, or electrical discharge machine. Seen here:

I know, it's a beast.


Basically, the graduate student I was working under said, "Read the operating manual." So I did!
The first words that the manual said, "'You may think that EDM stands for 'Evil Demon Magic.'  But it actually stands for 'Electrical discharge machine.'" I thought this way really funny and credited the Japanese company, Sodick, for having a sense of humor in its technical manuals.

This is how an EDM works:

• A wire (for this "wire EDM") is strung in water. Don't worry, the water is de-ionized so it doesn't conduct electricity.
• A large current is passed through the wire.
• The wire, basically, melts everything in it's path (as long as it's metal)
• The water washes the melted material away.

Once a grad student told me he stuck his hand in the water to take a picture of the process... I wouldn't recommend this action, but he was living proof that the water doesn't conduct electricity.

Funny story: Once I opened to front door to the EDM while the basin was filled with water.  You know what happened...

Water spilled everywhere! Afterward, my adviser laughed and said that he could never get the door closed after he opened it. I didn't feel so stupid afterward.

Big Machines: They aren't that scary.

I came to college not knowing ANYTHING about manufacturing or combustion engines. For you worry-warts out there: that's okay! A little secret: most of the guys in my classes didn't know either. 


Here's Serena's basics of manufacturing:

1. What is the design of your part? If the part's feature is circular: use a lathe (like how they make baseball bats!).  If the part is basically cutting away material in straight paths: use a mill or drill press (which makes holes). If it's super intricate, use an EDM (Electric Discharge Machine) but chances are you won't need one right away.
2. It's all about positioning.  Where does the tool go? Define the paths on paper (or in your head) before you even get CLOSE to a machine.  Easy enough. Actually sounds kinda fun. 
3. Figure out how the machine (mill, lathe, EDM) works.  A basic shop class will take care of this. Most of the hard work is done in your head. 
4. Manufacture your part! See...it wasn't that hard! 

Next post: my experience with EDMs and the Intron, a tensile testing machine.

How cool is that? Rapid Prototyping

I previously mentioned that was able to design and rapid prototype my Malroy part. What is rapid prototyping?

• It is a technology with places material layer-by-layer to make very intricate parts.
• Many of these parts cannot be manufactured using your everyday mill, lathe because the parts are too small or too intricate. 
• It is revolutionary, especially since computers. You can design your own trinkets, jewelry, or use something very specific for a hobby/project.
• Eg. The Malroy was a way to fit pins and clips together precisely.  I could have created a jig to put the part in, but the pieces are so small that this is hard to do. So my mentor told me to design something using Autodesk Inventor.  I did it in about 2 hours, and I had the part in my hands the next day.

Here's a video to show the cool stuff you can make!

Baltimore, MD

This past weekend, I had the opportunity to visit Baltimore.  It's about 30 miles from Washington DC.  However, it's an entirely different city in terms of industry.  I would describe it as similar to Detroit (as quoted by one of the friends, "Baltimore is Detroit 30 years ago.") with its aging of manufacturing.  It should be noted that the unemployment rate of young men (under 30 or so) is 30%.  This is very similar to the Great Depression. This is what happens when you move from manufacturing to a very technological age.

I do wish to note that Baltimore did remind me why my major is in mechanical engineering.  Manufacturing is a great industry. It truly shows a country's economic development.  There are so many different products that we encounter everyday, and we don't even think twice about how the item came to be in my hands.

Look at all the factories! Think about the number of people needed for this type of work.  I don't care if something is animated.  You still need people to organize other people and machinery to make something in a very quick, efficient way.  The transportation, manufacturing, food, beverages, movement of money, movement of raw materials, the energy needed to conduct all of this business! To be honest, I don't think the importance of engineering is marketed enough, especially in the country that we live in! We now have the ability to rely on other service items for our source of "innovation."  But our true innovation relies on the manufacturing that still exists today.  Sure, I know it's on the decline.  However, if you lose your backing of manufacturing, the country needs to rely on other countries for its sustenance.

From my manufacturing class, the three tiers of a economy:
1. Agriculture
2. Manufacturing
3. Service

Currently, the United States has moved more into the service industry.  However, it is reliant on those countries in the other two tiers.  Think about where America stand and your role in it as a proud member.