Japan Quality ALC400G ALC600G. The. Smart Linear. Smart Pulse

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1 Japan Quality The Smart Pulse & Smart Linear ALC400G ALC600G

2 The Spirit of Create, Implement and Overcome Difficulties Linchpin of manufac Based on the mindset of "assisting in the product development of customers", Sodick has listened to the demands of customers no matter how insignificant, and has challenged and overcome every difficult technical issue to solve problems. The company has also maintained the stance where Sodick even develop products in-house to solve a problem, if its solution is not available anywhere in the world. The origin of Sodick the company name, is derived from the spirit of not hesitating to "Create(So)", "Implement (di)", and "Overcome difficulties (ck)" for customers, and has become the company motto of Sodick.

3 Japan Quality The Creating Future Based on the founding philosophy Create, Implement, Overcome difficulties, Sodick strives to be a company that contributes to society by providing products of various kinds for future creation : creating a future that is energy-efficient, safe, and eco-friendly, a future with the state-of- the-art technology and with high hopes. cturing of the world Message from Management It is our mission to create and deliver machine tools that clients find rewarding to use. In our ceaseless commitment to our corporate principles of "Create, Implement and Overcome Difficulties, all the Sodick EDM machines are developed and manufactured in their own facilities and benefit from Sodick s unique in-house produced technologies; NC units, linear motors, ceramic components, discharge units and control systems. Sodick has made continuous growth in the European market thanks to the extremely high reliability levels of the machines with advanced performance. Sodick Europe s technical center is located in Coventry, UK from where we provide all the technical support, spare parts and consumables for our European partners. Peter Capp, CEO of Sodick Europe Ltd. The Japan Quality ALC400G ALC600G 2 3

4 Linear Motor Drive High Performance Wire-cut EDM Through in-house development and manufacturing of all elemental technologies including linear motors, discharge power supply, NC unit, motion controller and ceramics, the ALC400G and ALC600G delivers overwhelming performance based on the Smart Pulse & Smart Linear concept. ALC400G Japan Quality The 10-Year Positioning Accuracy Guarantee By adopting the linear motor drive system, array of applications previously deemed impossible with conventional ball-screw drive system was made possible by Sodick Wire EDM. Throughout machine life (over 15 years), accuracy will not diminish over time, and initial machine accuracy is maintained semipermanently. 10 Jahre Garantie auf die Positioniergenauigkeit

5 Integration of Sodick's linear EDM experience and know-how perfected over 15 years Sodick has launched a brand new Premium Wire-Cut EDM Series the ALC400G and ALC600G. Based on the latest digital innovations in generator technologies, the new ALC Premium range demonstrates considerable advances in cutting speed, accuracy and surface finish. This achievement was made possible through 15 years of Sodick Linear Technology. The Smart Pulse Generator drastically reduces the number of cuts necessary to achieve the required accuracy and surface finish, compared with conventional machines. This reduction in time translates directly into financial advantages. To capitalise on the advances of the digital Smart Pulse generator and Sodick s linear motor system, a new mechanical design was required. This new design resulted in a compact and fully enclosed machine tool which furthermore uses the latest human interface with a 19-inch touch screen control. ALC600G The Japan Quality ALC400G ALC600G 4 5

6 Electrical Discharge Power Supply Unit Japan Quality The The unit contains numerous circuits to optimally control electrical discharge energy. High speed, quality rough cutting essential for finishing is controlled through an optimum discharge pulse to achieve superior surface and form accuracy. The electrical discharge power supply unit To Realize Products Satisfying the World s containing these circuits is based on energy Strictest Standards, Sodick Develops the saving design that works to minimize Advanced In-house Made Core Technologies. wasteful energy loss. The development philosophy espoused by Sodick is If it does not exist anywhere in the world, we will create it. It is not an exaggeration to say that creation is the result of day-to-day problem solving. But, when we try to solve problems, we are blocked by barriers which we cannot break through with our present technologies and products. To break through these barriers, we have no choice but to create the means ourselves. NC EDM, linear motor drive EDM and other technologies, which are now a familiar part of the process of creation, were developed by Sodick so that all our customers can realize their ambitions; their NC Unit desire to produce good products to enrich Sodick develops and manufactures society. The process of Sodick s technology user-friendly NC units easily operable by revolution embodied by its innovations in the anyone, and yet provides supreme field of EDM, is now expressed with the words, machining performance. In order to achieve Total Manufacturing Solution, and is a long ultra precision machining, a built-in artificial process including total support for every step in intelligence is combined with Creation, extending from design to final state-of-the-art electrical-discharge production. Sodick will continue to listen to the machining technologies, which precisely voices of its customers, and constantly challenge controls the drive system through K-SMC, its limitations, to contribute to the achievement electrical discharge power supply, and wire of an abundant future and the advance of running system. creation in the world. Five Core-technolo Realizing Pr

7 Ceramics Due to the extremely small thermal displacement, ceramic is ideal material for use in electric discharge machines. In addition to perfect hardness, light weight, heat resistance, and low wear characteristics, ceramic has electric insulation properties as well, which is important for electrical discharge machines. By using ceramic components, high quality machining surface can be ensured in small areas without the need for any special jigs. SMC (Sodick Motion Controller) Linear Motor "The Sodick Motion Controller (K-SMC)" Sodick's linear motor provides high which accurately controls the high-speed acceleration and positioning accuracy and precise linear motor drive movements without backlash, by a direct drive through commands from the NC unit, was mechanism without any single command heavily researched and developed to bring delay. The excellent dynamic response, about new technical innovation to electrical stable machining accuracy and its discharge machining. Accurately controls performance does not deteriorate over long high-speed, rapid acceleration, and precise periods of operation without any positioning. maintenance. ogies for recision Machining The Japan Quality ALC400G ALC600G 6 7

8 NC unit The ALC Series is equipped with the all-new SPW Power Supply Unit with a Multi-touch LCD monitor to bring new innovations in operability. In addition, the unit is equipped with a high-speed dual core processor. With operability optimized with a LCD monitor system, the unit creates an innovative environment in which workers can perform all necessary work through simple touch operation. Link to the Special Website

9 Equipped with the NEW SPW Controller Newly developed High-speed motion controller 1 Gbit/sec high-speed serial communication K-SMC LINK Equipped with high-speed Dual Core processor Low power consumption Improved linear motor control performance New user interface NC Unit employs 19 Multi-touch LCD Coordinate Setup Screen Maintenance Screen Machining Condition Screen Workpiece Allignment Screen The Japan Quality ALC400G ALC600G 8 9

10 Smart Pulse Surface roughness, machining accuracy and machining speed can controlled freely The Smart Pulse (SPW power supply) demonstrates overwhelmingly high performance in all areas from the first cut to finish machining. The high peak current during rough machining to the extremely fine discharge pulse during superfine finish machining, Electrical Discharge Power Supply Unit The unit contains numerous circuits to optimally control electrical discharge energy. High speed, quality rough cutting are essential for finishing and are controlled through an optimum discharge pulse to achieve superior surface and form accuracy. The electrical discharge power supply unit containing these circuits is based on an energy saving design that works to minimize wasteful energy loss. can be controlled freely. The performance was TMP Control: improved in all machining areas, such as an This refines the roughness at the machining pass by continuous pulse control. improvement in the rough machining speed with the Straightness Error Elimination Control: "Hayabusa" wire, high precision and high-speed This enables high-precision and high-speed machining of thick plates. machining of thick plate by the barrel-free effect Digital PIKA Circuit: control, refined surface roughness of the second cut This improves the surface finish quality and enables optimum surface machining. by TMP Control, and improved the surface quality of finish machining by the Digital PIKA W Circuit. Link to the Special Website

11 Ultra Surface Finish ALC400G/ALC600G provides Digital PIKA W Plus as Standard. The transistor-generate current is optimized to save machining energy, also to prevent corrosion by electrolysis free circuit. Using Smart Pulse (High-speed & no electrolysis), Industry s best surface is given. Machining Speed ALC400G/ALC600G provides Ultra high speed & electrolysis free Smart Pulse TM circuit as standard. Smart Pulse prevents oxidation, weakening and corroding which occurs when using deionized water. Ionic current is controlled while providing high-frequency bi-polar short pulse into electrode gap, resulting in ultra high-speed & electrolysis free machining. TMP Control Corner shape 6 µm 6μm In addition to the high-speed machining performance of the first cut, the TMP Control of the Smart Pulse (SPW power supply) demonstrates its out-standing ability in refining the surface roughness of the second cut by 50% of the Ra value. The surface quality and shape accuracy including corners with the TMP Control, Wire tension servo function: Wire travels at a stable tension Digital PIKA W Plus Circuit: Uniform best surface roughness Thickness Wire diameter realizes "machining of precision fitted components" in the second cut. 15 mm Ø 0.2 mm (Hayabusa wire) Cemented carbide Ra 0.04 μm (Rz 0.34 μm) Superior Corner Control Machining is improved to prevent corner wear on both in & out corner. The predictive control processes optimal control at angle and corner shape before machining. The corner control can control while simultaneously modifying the complicated machining parameters automatically. Steel Ra 0.09μm (Rz 0.91 µm) High Speed Step-shape Machining DSF Dynamic Shape First Linear motor drive provides superior sensitivity and adapts the effect on thickness change. Thinking circuit automatically detects thickness and processes optimal machining parameters. Thick workpiece can get 1-2μm straightness. Taper Cutting Control High precision fitted machining (Varying top and bottom shapes) cut shape accuracy by Taper Flex Neo* of 3 μm/one side target (*Option) The Japan Quality ALC400G ALC600G 10 11

12 Since 1998 when linear motor drive system was first introduced to the industry, over 40,000 machine products have been delivered globally with more than 15 years of track record for its long-term reliability and performance. Smart Linear Comes with world standard Heidenhain linear scale Sodick'S Linear Technology High Precision & Sensitivity Employs a projection method linear scale which The linear motor has proven to be highly reliable and durable from the 10 uses projected light as a signal. Encoder scale with extremely fine grid interval Guarantees minimum position error. As soon as the power is switched ON, position data is acquired from the encoder. Origin position search motion is unnecessary. Reduction of years of shipments. It does not require the maintenance-cost for replacing the ball-screws 10 years after shipment origin return time For the X,Y,U, & V axes (4 axes) High Durability in drive performance Link to the Special Website

13 Sodick Motion Control In Real-Time Unlike traditional position control system where NC controller monitors discharge gap and sends feed back through motor driver, Sodick motion controller delivers real-time control with optimal gap control while direct-monitoring discharge energy conditions. This provides high precision positioning with high sensitivity K-SMC(Sodick Motion Control) provides ultimate gap control The Axis movement performance with a Ball-Screw Drive system will deteriorate over time because of lost-motion due to mechanical backlash, whist a Linear motor Drive delivers smooth backlash-free movement. Its simple non-contact structure does not suffer from mechanical wear or deterioration. The initial accuracy of the Direct Linear Drive is maintained over a long productive period without the need for expensive maintenance. Linear Motor Drive Machines Over 15 years, More than Units Around the World 4-axis linear motor drive The linear motor drive system is cleverly designed to operate for many years trouble-free and used in conjunction with an absolute linear scale by Heidenhain. With excellent position detection performance and stability, the absolute linear scale has a resolution of 0.01μm. The Japan Quality ALC400G ALC600G 12 13

14 Machine Con The machine has a variety of standard built-in functions, including a new tension servo function, auto fluid-level control, and the new FJ-AWT in the field, a square-shaped work stand, ceramic Triple Filter (Dielectric tank) and O-Shape Worktable stand base, 3-sided machining tank with Paying close attention to machine accessibility for work preparation in the automatic lifting door, triple filter and many other field, Triple filter and O-shape worktable comes standrd. (Automatic Wire Threader). Paying close attention to the machine accessibility for work preparation features, all of which works to ensure improvements in productivity. Furthermore, by adopting a unique full-cover machine structure, comfort and safety in the work environment is not compromised. Link to the Special Website

15 Sodick Own Ceramic with Excellent Insulation Ceramic work stand ensures high rigidity and long life accuracy. Sodick developed its own Ceramic table for work stands and guides on all machines, So, long life of high insulation and high accuracy are provided. Also low thermal distortion of ceramics helps higher machining accuracies. nstruction Slide-plate Cleaning Function (Flushing) To maintain long life of sealing on the work tank, self-cleaning system is equipped. Automatic 3-side Vertical Sliding Tank Door ALC series adopts 3 sided vertically sliding machining tank door as standard for operators accessibility. This also ensures the future automated operation with robot systems. The Japan Quality ALC400G ALC600G 14 15

16 FJ-AWT The FJ-AWT (Fixed Jet AWT) has excellent wire connection rate and connection speed, together with annealing system, further improving the wire connection rate and the wire straightness. Diamond guide Diamond round guide with small clearances realises high-precision machining. * Please use genuine consumable supplies. Threading into curved surface Pop-up Search Function FJ-AWT does not require the water-jet support for threading Successful in the threading of multi-cavity die component the wire. machining where there are multiple hollows! The wire is pulled Jet-less threading mode!! Threading reliability is improved in upward by pop-up air, and the search function operates slopes and curved surface on a workpiece whenever immediately. Reliable threading even in shapes that are difficult water-submerged or not. to thread with the pop-up search function! Narrow clearance 0.05 wire AWT Excellent machining performance due to narrow clearance die Automatic wire threading for thin wire (ø0.07 and 0.05mm) is available as an option. HTP circuit is also included to apply a higher voltage.

17 High-Speed&Ecology-Wire Hayabusa wire Achieves a barrel amount of 2 µm/one side of a 200 mm thick plate in four cuts The "Hayabusa wire," is different than common zinc coated wire, where the zinc is permeated into the brass wire. Since there is no formation of a zinc layer, there is no occurrence of powder caused by the removal of the zinc, or an exces-sive electrical discharge. Accordingly, lines and waviness do not occur so easily, which stabilizes the shape accuracy. Difference between Hayabusa wire and zinc coated wire Hayabusa wire Zinc coated wire [Cross section] Zinc permeated the brass Workpiece material [Cross section] Steel Thickness Zinc 200 mm Machining accuracy Brass ±2 µm Surface roughness Ra 0.35 µm (Rz 2.8 µm) Wire diameter Ø 0.25 mm (Hayabusa wire) No. of cuts (Photographed with x500 lens) 4 (Photographed with x500 lens) Hayabusa Wire + ECO Conditions Selectable Standard Conditions The "Hayabusa wire" with excellent high-speed, reduced the Surface roughness wire usage amount by 10% or more with a surface rough-ness Machining accuracy ECO conditions of Ra 0.38 µm by the condition search function "ECO Conditions" of Sodick's database (STD Conditions). ECO Conditions Workpiece material SKD11 Thickness 40 mm Surface roughness Thickness Machining time Amount of wire used (STD Conditions) 40 mm 2 h 19 min 1206 m (1435 m) Wire diameter No. of cuts Workpiece material SKD11 Thickness 80 mm Surface roughness Wire diameter No. of cuts ECO Conditions Thickness Machining time Amount of wire used (STD Conditions) 80 mm 4 h 27 min 2793 m (3025 m) Ra 0.38 µm (Rz 2.8 µm) Ø 0.2 mm (Hayabusa wire) 4 Ra 0.37 µm (Rz 2.8 µm) Ø 0.2 mm (Hayabusa wire) 4 Machining conditions search service Machining conditions search service (Selection screen of machining accuracy) The machining conditions can be set by simple operation, just by selecting and entering the wire diameter, workpiece mate-rial, thickness and etc. to be used. The balance between the target surface roughness and the ma-chining accuracy can be checked at a glance and selected. The Japan Quality ALC400G ALC600G 16 17

18 Automation 20kg Wire Feeder Built-in wire feeder is available as standard for wire bobbin up to 20kg which allows continuous operation. L-Cut (wire chopper) The ejected wire is chopped into small pieces for easy disposal. (Optional)

19 Taper flex Neo 45 Taper flex Neo 45 is available as an option for accurate large angular machining up to 45. Taper Flex Neo 45 is easy to use and requires no special training. The option consists of three parts: High Angle Guides, a Calibration Jig and Software. Multi-Axis Capability Sodick s SPW-E Power supply Control is capable of controlling up to 8-Axis simultaneously. The Multi Axis Control is available as a factory-fi t option. ANCS (Anti Corrosion System) The ANCS prevents rust, corrosion and discoloration on workpieces electrically and chemically while they are being machined or left in the dielectric. This advanced rustfree system is effective for steel, carbide and alloys and available as a factory option. WS-4P/5P Sodick s own Rotary Table developed In-house is available as an additional A or B axis for indexing or simultaneous contouring. (Optional) The Japan Quality ALC400G ALC600G 18 19

20 Samples Japan Quality The Smart Pulse & Smart Linear Improves Machining Performance in All Wire-cut EDM Applications. Surface roughness of second cut is Ra 1.6 µm or less Workpiece material Steel Thickness 100 mm Surface roughness Ra 1.6 µm (Rz 11 µm) Wire diameter Ø 0.2 mm (Hayabusa wire) Machining time No. of Cuts 90 min Time to Cut (min) Surface Roughness: µm Rz16 Ra Rz12 Ra Finishes precision fitted components in two cuts Workpiece material SKD11 Thickness 40 mm Machining accuracy ±3 µm Surface roughness Wire diameter Machining time C(24.997mm) Ra 1.37 µm Ø 0.2 mm (Hayabusa wire) top 2 h 25 min No. of Cuts Time to Cut (min) middle bottom Reduced Machining time for each cut (hrs.) ALC machine 41 % Conventional machine 0 1 3rd Machining time for each cut (hrs.) Improved shape accuracy and surface quality with reduced number of cuts ALC machine Conventional machine Machining time for each cut (hrs.) 0 ALC machine Conventional machine 3rd rd Improved machining accuracy Workpiece material Thickness Machining accuracy Surface roughness SKD mm ±3 µm Ra 1.42 µm (Rz 9.58 µm) Wire diameter Ø 0.25 mm (Hayabusa wire) Machining time 13 h 17 min (1 set, 2 shapes) Reduced 39 Machining time for each cut (hrs.) ALC machine Conventional machine 0 Sample disclaimer:- All cutting results contained herein have been achieved under Sodick designated conditions and Sodick measurement conditions. % 5 3rd 10 15

21 ALC400G ALC600G The machining performance of wire-cut EDM has significantly improved in all areas due to the synergistic effect of combining linear motor drive technology and the latest discharge control technology with Smart Pulse power supply. Sodick has achieved increasing machining speed with a straightness error bow-belly amount of 2μm/side, machining surface roughness of Ra 1.6μm, and precision area machining surface roughness of Ra 0.04μm. Uniform shape accuracy in the top, middle and bottom of a thick plate 4 cut machining of precision fitted components The excellent machining performance of Smart Pulse (SPW power supply) realized machining of precision fitted com-ponents of a 100 mm thickness. Shape accuracy with high straightness can be finished with 4 cuts. Workpiece material Thickness Machining accuracy Surface roughness Wire diameter Machining time Reduced 32 SKD11 Machining time for each cut (hrs.) 100 mm ±3 µm ALC machine % Ra 0.20 µm (Rz 2.10 µm) 3rd Ø 0.2 mm (Hayabusa wire) 2 h 57 min 0 Thick cemented carbide plate Machining of precision fitted components 4th 1 2 5th 3rd Machining time for each cut (hrs.) ALC machine Machining time for each cut (hrs.) Barrel-free effect control: cut barrel effect 2 µm/one side Wire tension servo function: Wire travels at a stable tension Digital PIKA W Circuit: Uniform surface roughness finishing even with thick plate Electrochemical anti-corrosion technology rust-less (Option): Suppresses the elution of cobalt and ensures edges 4th Conventional machine Workpiece material Conventional machine ALC machine Thickness 180 mm 0 Machining accuracy 1 2 3rd ±3.0 µm 4th Surface roughness Conventional machine 3rd carbide 4th Cemented 4th 5th 3rd 3 4 4th 5th Wire diameter1 Ø 0.2 mm (Hayabusa wire) Ra 0.27 µm (Rz 2.353rd µm) Machining time 3 1 h 20 min (1piece) Reduced 38 Machining time for each cut (hrs.) ALC machine % 3rd Conventional machine 0 4th 4th 1 5th 3rd 2 3 Core pin shape 2 step machining where the thickness changes between 0.3 to 1.0 mm The ALC Series is equipped with a Wire Tension Servo Function by Sodick's unique motion control K-SMC (Sodick Motion Controller). Accordingly, this function responds to the changes in the thickness of fine shapes, and performs high precision machining with the ideal tension control. Even with thin wire, the deflection of the wire is suppressed to realize stable and high precision machining with high efficiency. Pitch 0.6mm Super Finishing Digital PIKA W Circuit 4 cuts Ra 0.24 µm (Rz 2 µm) The Smart Pulse (SPW power supply) realizes a surface finish with a uniform surface roughness even in highly difficult machining of 26 times the aspect ratio, utilizing the super finishing Digital PIKA W Circuit for the final cut. 33 pin 2-layered Pitch 0.6 mm Workpiece material Thickness Machining accuracy Surface roughness Wire diameter Machining time Steel 0.3 to 0.1 mm ( 2 layers) ±2.0 µm Ra 0.24 µm (Rz 2.05 µm) Ø 0.1 mm (Hayabusa wire) 3 h 48 min The Japan Quality ALC400G ALC600G 20 21

22 Specifications Machine tool ALC400G ALC600G X Axis travel 400 mm 600 mm Y Axis travel 300 mm 400 mm Z Axis travel 250 mm 350 mm 150 x 150 mm 150 x 150 mm ±25 ± x 610 mm 1050 x 710 mm 500 kg 1000 kg 0.1 ~ 0.3 mm 0.1 ~ 0.3 mm 3 ~ 23N 3 ~ 23N 420 mm/sec 420 mm/sec 995 mm 995 mm 2115 x 2500 x 2230 mm 2495 x 2895 x 2345 mm 3350 x 3865 mm 3780 x 4245 mm 3400 kg 4600 kg 3-phases 50/60Hz 13KVA 3-phases 50/60Hz 13KVA Dielectric Tank ALC400G ALC600G External dimensions (W x D) 700 x 2155 mm 790 x 2505 mm Empty weight 400 kg 600 kg Capacity 600 lit 800 lit 3 Replaceable paper filters (internal pressure) 3 Replaceable paper filters (internal pressure) Ion exchange resin (18-lit. type) Ion exchange resin (18-lit. type) U x V Axis travel Taper angle (Work. thickness 130mm) Work tank dimensions (W x D) Max. workpiece weight Wire diameter Wire tension Max. wire speed Distance from floor to table top Machine tool dimensions (W x D x H) Machine installation dimensions Machine tool weight Total power input Dielectric fluid filtration system Deionizer *Due to ongoing research, specifications are subject to change without prior notice ALC400G ALC600G Brochure disclaimer:- The products described herein this literature can be subject specification change without notice to improve capability, design or function.

23 Druckluftanschluss ALC400G ALC600G Top View Versorgungskabel 200/220 V AC (50/60 Hz) Top View Drahtabfallbehälter Versorgungskabel 200/220 V AC (50/60 Hz) Ablauf 1B Ablauf 1B Drahtabfallbehälter De-Ionisier-Patrone De-Ionisier-Patrone De-Ionisier-Patrone Druckluftanschluss Versorgungskabel 200/220 V AC (50/60 Hz) Drahtabfallbehälter Druckluftanschluss Ablauf 1B (unit : mm) De-Ionisier-Patrone ALC400G Workstand Layout ALC600G Workstand Layout st 1066 The Japan Quality st 400 st 400 st st st 300 st 300 st Druckluftanschluss 1066 ALC400G ALC600G 22 23

24 Create your future Sodick Europe Ltd. Kontakt zu Sodick Rowley Drive, Baginton Coventry, CV3 4FG United Kingdom Telefonisch +44 (0) per Website Printed in Japan S <00>