ELECTRICAL DISCHARGE MACHINES

DRILL SMALL HOLES FAST
Mitsubishi (Wood Dale, IL) offers the ED6000S CNC small hole EDM drill, with improved positioning speed on the X, Y, and Z axes that is five times faster than on previous models. An increased W-axis speed reduces positioning time between holes and electrode exchange time, boosting overall small-hole production.

The ED6000S has a M730 Series Mitsubishi control that provides the flexibility to run more advanced programming, while the Windows XP-based, 15 in touch-screen display delivers ease of operation. A collet-type chucking system provides more dependable clamping of smaller electrode tubes. Constant Processing Circuit (CPC) reduces and improves the wear characteristics of the electrodes. The new power supply is fine-tuned for small-hole applications and offers wider range and finer steps in the electrical power setting adjustments. These include On-Time, Off-Time and IP settings.

The ED5000S shares all of the features and programming benefits of the ED6000S without the automatic tool changer and guide changer. www.mitsubishi-world.com

MIRROR-LIKE SURFACE FINISHING,
NEXT GENERATION WIRE EDM
Makino (Auburn Hills, MI) designed the UPV-3 and UPV-5 Ultra-High Precision WEDM with an oil-based dielectric fluid system for high-accuracy machining of hardened materials and mirror-like surface finishing capabilities.

“The oil-based dielectric fluid system design of the UPV series is completely different from our other EDM machinery, offering multiple unique benefits,” says Jeff Kiszonas, EDM product manager. “We’ve integrated a thermal control system that maintains constant dielectric and casting temperatures, the latest SPG II circuit for improved finishing operations, and our proven high-performance PICO guide system. Together these features create a rigid, reliable, high-accuracy machining platform capable of producing surface finishes to 0.08 μm Rz.”

Makino’s UPV machines feature a fixed-table design in which axis movements are controlled by machining heads. Sizes of the UPV-3 and UPV-5 are 101.57 in x 126.97 in (2580 x 3225 mm) and 113.58 in x 131.30 in (2885 x 3335 mm) with X, Y, and Z axis travels of 14.57 in, 10.63 in, 8.66 in (370, 270, 220 mm) and 21.65 in, 14.57 in, 8.66 in (550, 370, 220 mm) respectively.

Included in the UPV design are ceramic insulators placed between the worktable and machine casting to reduce stray electric capacitance and enable the SPG II machining circuit to stabilize micro electrical discharges. Utilizing these capabilities under standard machining conditions for a 20 mm (0.79 in) thick work piece measuring up to 100 x 100 mm (3.93 in x 3.93 in) users can achieve 0.2 μm Rz surface finishes. The table’s electrically conductive machining area can also be limited for jobs requiring a surface finish better than 0.2 μm Rz. This further reduces stray electric capacitance for surface finishes down to 0.08 μm Rz (actual measured value).

In similar performance tests using carbide, the UPV machines performed up to 22 percent faster than water based machines, and up to 78 percent faster than prior oil based technology with good sealed flushing.

The machines’ oil-based dielectric fluid systems create a smaller spark gap between the electrode and work piece than standard water-based fluid systems. This facilitates precision machining of narrower slot widths and smaller corner radii in a variety of materials, including hardened metals and polycrystalline diamond (PCD). Using oil-based dielectric fluid also eliminates the soft layer that can result from the EDM process and surface corrosion caused by electrolytic action. In long-run applications where machined parts remain submerged for extended periods, this can be critical in controlling corrosion or oxidation layers susceptible to these effects.

The UPV’s bed tank system provides enhanced thermal control by circulating temperature controlled dielectric fluid through the machine’s lower castings. Simultaneously, Makino’s temperature-control functions adjust air temperatures to that of the dielectric fluid and direct airflow through the machines’ upper castings. Controlling the machines’ cast-iron parts to the same temperature in this way minimizes changes in machine attitude.

Next-generation wire EDMs, called the DUO series, enhance performance, accuracy, speed, ease of operation and maintenance with features such as dual wire guide options, DuoSpark generator, dual anchored ball screws, and dual high pressure flush pumps.

“This is really the next step in Makino’s wire EDM design,” states Kiszonas. “With recent technologies such as HEAT, SurfaceWIZARD and PICO guides, our machines have revolutionized EDM. The DUO series takes these advancements a step further, and will enhance our ability to serve more customer’s needs and provide the most technologically advanced, yet simple to operate, wire EDMs available.”

The DUO series features two models, the DUO43 and DUO64. Both models feature a 20 percent reduction in footprint size compared to their Makino SP-series counterparts. The sizes for the DUO43 and 64 are 74.8 in x 102.3 in and 82.7 in x 122 in with X-, Y-, and Z-axis travels of 17.7 in, 12.0 in, 12.6 in and 25.6 in, 15.7 in, 16.5 in respectively. The DUO43 will accommodate a maximum work piece size of 27.9 in x 22.0 in x 11.8 in with a payload of 1764 lb, while the DUO64 holds sizes up to 35.8 in x 26.0 in x 15.7 in with a maximum payload of 2200 lb. This series was designed to provide a smaller footprint and ease of installation, without sacrificing work area.

Whether the application is small hole threading, threading small holes in close proximity, maintaining land accuracy in contoured stamping dies, cutting tapers up to 45 deg, or general WEDM job shop work, Makino is the only WEDM builder that provides a guide solution to every WEDM application. This option provides split precision guides for most general work including high tapers, and PICO precision guides for accurate threading of small holes in close proximity, highly accurate tapers and taper transitions up to 10 degrees, and maintaining variable height land details.

The units feature DUO Spark Generator technology, which utilizes unique spark waveforms with multiple ON and OFF times, almost like using two E-codes at one time. This assures delivery of consistent spark energy that provides superior performance in speed, finish, and accuracy, while improving energizer life and performance

The series’ dual high-pressure flush pumps provide independent control of upper and lower head flushing jets. The pumps can provide pressure up to 290 psi to improve roughing speeds and aid in producing superior surface finishes. By circulating through two pumps, one for each machine head, the DUO is able to improve efficiency over wire EDMs containing only a single pump, reduce mechanical failures, and achieve finer finishes.

The pumps are independently controlled and monitored through the controller, allowing faster adaptation to changes during machining operations and providing higher quality parts in shorter cycle times. This design provides its greatest advantages during detached nozzle applications (poor flush), and further improves the performance of Makino’s HEAT technology.

With dual anchored ball screws, the DUO series provides a rigid construction for long-term sustained accuracy and precision. Backed up by a 10-year/20,000-hour ball screw guarantee, the DUO Series is built for long-term repeatability and reliability.

Other dual features include dual work tank doors to accommodate loading of large work pieces and work area access without draining and refilling the work tank, dual feedback to assure accuracy and repeatability of movement and positioning over a long period of time, unsubmerged dual filter banks with automatic water evacuation, dual control operation that allows use of either the mouse and keyboard or the full function remote hand box, and dual head protect functions for crash protection capability to help reduce or eliminate damage caused by unexpected collisions. www.makino.com

ULTRA-PRECISION MICRO-MACHINING
The CUT 1000 from GF AgieCharmilles (Lincolnshire, IL) is designed specifically for micro-machining and ultra-precision applications that are as productive as it is precise. The machine is equipped with AC Duo, which makes it possible to work with two wire spools, each with a different wire type, and switch between wires of different diameters automatically. Programmable via the machine control, the forward feed of the wires, just like the threading, takes place automatically and is monitored by patented sensors.

The CUT 1000 table design separates the X and Y axes on a patented monobloc, eliminating mutual interference and tripping errors. A traveling table on the machine bed carries the work tank and moves the work piece in the X direction exclusively. A second axis slide, also movable in the horizontal plane on the machine frame, accommodates the upper part of the C-frame and moves the wire in the Y direction. This configuration delivers ideal travels, positioning accuracy and taper cutting capability for machining complex, high precision parts.

The CUT 1000 accommodates work pieces up to 77 lb and has X-, Y- and Z-axis travels of 8.66 in x 6.29 in x 3.93 in. Additionally, CUT 1000 is equipped with Vision 5, an intuitive control system developed specifically for wire cut EDM that enables flexible data input in accordance with workshop environment.

The CUT 1000 OilTech makes surface protection a priority while also serving as a highly accurate wire EDM. It uses wires as small as .02 mm diameter and SF technology to achieve surface finishes down to Ra 0.05 µm in continuous operation and impeccable corner quality. The system uses oil as an inert dielectric.

The oil eliminates the effects of corrosion due to long periods of immersion in the work piece. As a result, multiple work pieces can remain immersed in the dielectric for overnight or weekend machining needs. The oil also enables smaller distances between the wire and work piece to produce smaller internal radii when compared to water-based machining.

This system is as productive as it is precise. Equipped with a high-performance generator and the AC Duo wire system, the machine is able to work with two wire spools, each with a different wire type, and switch between wires of different diameters automatically. Programmable via the machine control, the forward feed of the wires, just like the threading, takes place automatically and is monitored by patented sensors.

The CUT 1000 OilTech uses its table design to separate the X and Y axes on a patented monobloc, eliminating mutual interference and tripping errors. A traveling table on the machine bed carries the work tank and moves the work piece in the X direction exclusively. A second axis slide, also movable in the horizontal plane on the machine frame, accommodates the upper part of the C-frame and moves the wire in the Y direction. This configuration delivers ideal travels, positioning accuracy and taper cutting capability for machining complex, high precision parts. www.gfac.com/us

REDUCE ENERGY COSTS
GF AgieCharmilles has a new range of FI CCS wire EDM machines that are not only fast and reliable, but also energy efficient and environmentally friendly. Designed to reduce operation costs, the high performance line helps customers break into a variety of high precision manufacturing sectors by providing increased productivity, versatility and safety.

The FI 240 CCS, FI 440 CCS and FI 640 CCS are equipped with high-performance ball screw collision protection technology, CleanCut digital generators and ECONOWATT, an energy-saving technology that enables machines to switch automatically to ‘sleep mode’ once machining operations are completed. These machines use four filters instead of two, reducing filtration costs by 25 percent and decreasing clogging. Additionally, each FI CCS model features exclusive Econotec technology, which reduces wire consumption by 25 percent when used with a .30 mm wire.

The FI 240 CCS wire EDM combines groundbreaking ease-of-use with maximum reliability, proven performance and world-class speed. Flexible and fast, the FI 240 CCS is the smallest of the CCS series and features a high XYUV feed-rate of 2 ips. The machine is equipped with the energy-efficient FI CC digital generator.

From roughing to finishing, the generator is ‘zero voltage’ to protect parts against electrolytic effects. As a result, users benefit from dramatically improved machining speed and surface integrity, as well as exceptional clean surface quality of less than RMS 4 µin of machined material. Additionally, the generator allows the FI240CCS to machine materials with a wide variety of wire diameters at a 38-in²/hr industrial cutting speed, and realize perfect quality, high precision work pieces with a surface roughness of Ra 0.1 μm.

ThermoCut 2 and Integrated Collision Protection (ICP) come standard on the FI 240 CCS. ThermoCut 2, a unique high-speed and maintenance-free wire threading system, boosts productivity by stretching wire and cutting it under the effect of heat, bringing the spark-to-spark time down to less than 24 seconds. Additionally, the collision protection works effectively at a high XYUV feed-rate of 2 ips, allowing the FI240CCS to cut variable work piece thicknesses such as mold inserts without any witness marks.

The new FI CCS machines offer cutting speeds in excess of 400 mm2/min, as well as large diameter and small wires for rough cutting operations. The ability to use larger diameter wires reduces the number of cuts required to produce the finished part, enabling each machine to achieve Ra .6 µm surface finishes in three cuts and Ra .3 µm in four cuts. The FI CCS machines also offer exceptional accuracy and precision, and feature Integrated Collision Protection (ICP) on the X, Y, U and V axes to enable rapid rates of 3 m/min to be achieved and maintained without the danger of collisions. www.gfac.com/us

EXCEL IN MICRO-MACHINING
The FO350 MS diesinking EDM from GF AgieCharmilles offers precision, speed and productivity for even the smallest die and mold applications. The FO350 MS pushes the limit of quality and profitability to meet the most demanding market challenges, excelling at machining components for the automotive, aerospace, connector technology, medical and watch-making industries.

To achieve superior quality and efficiency, the FO350 MS utilizes MicroTEC discharge circuitry, which enables EDM power to be modulated, with the flexibility necessary to maximize material removal, while allowing a reduced electrode undersize of ≤ 0.002 in. This allows for higher machining outputs, while maintaining the geometry of the electrodes due to an extremely low wear rate. Additionally, an increase in Z-axis motion speed and acceleration allow the FO350 MS to improve performance by approximately 30 percent for medium to deep rib machining.

FO350 MS also includes a double thermostabilization system, a world first in preventing the impact of temperature variations, allowing for maximum accuracy. Pulsed air, circulating in the cabin, is cooled in real time according to the temperature of the dielectric, by a double differential temperature probe. The whole of the main frame and the X, Y and Z axes are thermostabilized in the same way as the whole of the machine. Circulation of the dielectric is integrated into the worktable, which prevents the risk of thermal shocks when filling the tank.

Additionally, FO350 MS features DPControl that is designed to suggest ideal electrode undersize and rationalize the number of electrodes necessary for effective machining. The system allows direct access to measurements performed on a preset station and allows for organization of jobs according to the users priorities. DPControl also enables close monitoring with the automated production features of Expert Systems, and all information related to machining status can be transmitted directly to the operator via SMS. www.gfac.com/us

HIGH SPEED PRECISION FOR MOLDMAKERS
The FO350SP diesinking EDM from GF AgieCharmilles increases productivity and enables fine, shiny surface finishes of unmatched homogeneity. The machine’s high-speed Z-axis and “Speed Finishing” module make it perfectly suited for the machining of deep ribs, pre-roughed 3D cavities and “blade” type applications. The FO350SP features modular, autonomous running time solutions that extend the number of effective EDM hours.

The FO350SP uses a double thermostabilization system, a first in preventing the impact of temperature variations, allowing for maximum accuracy. Pulsed air, circulating in the cabin, is cooled in real time according to the temperature of the dielectric, by a double differential temperature probe. The whole of the main frame and the X, Y and Z-axes are thermostabilized in the same way as the whole of the machine. Circulation of the dielectric is integrated into the worktable, which prevents the risk of thermal shocks when filling the tank.

The FO350SP features DPControl that evaluates a completed job by automatically creating a full report on job execution readily accessible to the operator via the network or directly on the machine. The machine has Accura-C, a high precision C-axis that provides a dramatic increase of positioning accuracy, ensuring down to 3.6 Arc seconds.

To counteract the effects of pulsation movements in the dielectric fluid and increase stability, the C-axis is built to withstand maximum inertia of up to 1708 lb in². This boosts productivity and allows precise machining with electrodes weighing up to 110 lb. Additionally, Accura-C features a liquid cooling system to eliminate inaccuracy from thermal instability.

A Renishaw probe is available as an option with the FO350SP. This high precision measurement probe ensures perfectly accurate positioning to within a micron, by using optical transmission from a light beam. This optical probe is more precise and reliable than an electrical touch system. www.gfac.com/us

UNMATCHED HOMOGENEITY
The FO550S, a diesinking EDM from the “Speed Edition” range of GF AgieCharmilles increases productivity and enables fine, shiny surface finishes (≤ 0.4 µm) of unmatched homogeneity. With the movement speed of the Z-axis multiplied by two (295 in/min) and acceleration increased by five (197 in/s²), the FO550S excels in blade-type applications and pre-roughed 3D cavities.

The FO550S uses a double thermostabilization system, DPControl, and is equipped with Accura-C. A Renishaw probe is available as an option with the FO550S. This high-precision measurement probe ensures perfectly accurate positioning to within a micron, by using optical transmission from a light beam. This optical probe is more precise and reliable than an electrical touch system. www.gfac.com/us