Technical advances continue to recommend. EDM Technology Trumps Offshoring. Electrical Discharge Machining

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1 EDM Technology Trumps Offshoring Photo courtesy GF AgieCharmilles Preferred process for mold and die, close tolerance parts Photo courtesy GF AgieCharmilles Technical advances continue to recommend EDM for applications where the closest tolerances and finest surface finishes are required. Traditional industry applications include aerospace, medical device manufacturing, and large molds and small precision diemaking. EDM, like other advanced manufacturing technologies, is getting a much-needed boost from the improved appetite for manufacturing in North America, according to Glynn Fletcher, president, GF AgieCharmilles (Lincolnshire, IL). Reshoring, or right shoring to the US, the trend means that a lot of organizations want to be close to the largest market in the world. That strategic shift in how manufacturers are making their choices gives machine tool builders the opportunity to help manufacturers differentiate themselves from the competition by acquiring productivity-improving technology. August 2012 ManufacturingEngineeringMedia.com 179

2 At IMTS 2012, GF AgieCharmilles will have two booths, one in the South Hall where it will exhibit machine tools and services and one in the East Hall where it will promote its Uptime Plus aftermarket products and services. We have some 8000 machines in operation in North America, and we ve developed programs to help our customers make better use of the machines they have, says Fletcher. We have developed high levels of EDM and machining center technology so that when our customers decide to replace equipment, we have what they need available. Industry Focus Showcases EDM Technology GF AgieCharmilles South Hall booth will be divided into quadrants: Aerospace and Aeronautics; Medtech (medical industry applications); Mold and Die; and Aftermarket. Mold and die makers who are cutting a lot of carbide stamping dies, for example, should consider a high-end oil dielectric wire EDM machine. The technology prevents leaching of carbide for better surface integrity and a lot less cobalt depletion, Fletcher advises. Other technology advances to be shown include automatic wire changing, on-machine optical inspection for adjustments in the work zone, and laser ablation for creating textures on molds. We ll also repeat the e-manufacturing cell done in cooperation with EOS and its additive manufacturing technology, and a Mikron high-speed machining center and an EDM for finishing. Mitsubishi EDM s newest MV wire machine features design and engineering improvements, including noncontact cylindrical drive technology, an improved power supply, auto threading, and new methods of reducing operating costs, says Greg Langenhorst, technical marketing manager, MC Machinery Systems Inc. (Wood Dale, IL). Our wire EDM is introducing Cylindrical Drive Technology, which is using linear shaft motors that feature a noncontact round magnetic shaft that creates a full 360 of magnetic flux in place of a ballscrew drive system. The design eliminates the typical wear and backlash issues of a ballscrew and the normal cogging and cooling issues of a flat-plate type linear drive system, resulting in improved energy efficiency, accuracy, and speed. It s a very smooth and cool operating system as we have removed all the nonfunctional iron out of the system. The cylindrical drive technology is part of the ODS Optical Drive System that uses an all fiber Photo courtesy MC Machinery Systems optics servo control system that is said to be four times faster than a hard-wired system, allowing it to respond faster to the demands of the machine as far as maintaining a continuous spark gap and achieving a smooth finish. Power Supplies Head List of Advances The new V350 type 5 power supply with the new digital matrix sensor now shapes each spark pulse to remove more workpiece material while creating less damage to the wire. This results in the ability to slow the wire speed down which can reduce wire costs by up to 60% in typical punch and die type cutting where several skim cuts are used. The machine construction, especially in the smaller MV1200 size, has undergone a redesign, says Langenhorst. It features a split table rather than the compound table movement of our previous model. The table moves in X and the column moves in Y, both mounted to the same base 180 ManufacturingEngineeringMedia.com August 2012

3 casting eliminating any issues inherent to the stacked table arrangement. The new MV machine combines the speed of a V-type generator with fine-finishing and accuracy circuitry needed for toolroom applications. Also, the new auto-threader is annealing about a 14" [356-mm] long length of wire which reduces the curl to 10% or less and which improves rethreading through the gap, threading through taller parts, smaller holes, and deeper when the tank is submerged, Langenhorst says. According to Stephen Bond, national sales manager, Fanuc EDM, Methods Machine Tools Inc. (Sudbury, MA), during the last several years much of the technology advancements in EDM were in power supply and software technology to increase cutting speeds. Power supplies have been refined for better finishes in many different materials that are difficult to machine conventionally. Control software advancements have led to increased straightness in taller work, more precise corners and, again, improved finishes. At IMTS, Methods will demonstrate the new Fanuc Wire EDM control and power supply interfaced directly to a tilt/rotary table that makes it possible to produce medical and aerospace parts with virtually no recast. Wire EDMing PCD [polycrystalline diamond] has been vastly improved on Fanuc Wire EDMs due to a proprietary power supply specifically designed for this material. The demand for PCD inserts used in both metal and wood cutting tools has more than tripled over the last few years and the ability to cut PCD with no secondary finishing has allowed manufacturers of the these tool to offer quicker deliveries and reduce overall costs to manufacture the tools, Bond continues. Wire EDM has been used to cut PCD since the 1980s, but not until software program generation coupled with an improved or refined power supply was generated could these tools be machined competitively on a wire EDM. Now the new advancement in EDM control processors combined with exclusive software and the ability to probe the tool very August 2012 ManufacturingEngineeringMedia.com 181

4 accurately allows these tools to be machined untended. Methods has delivered several fully automated cells, utilizing Fanuc robots to manufacture PCD tools without operator intervention. Only once the tools are cut complete are they handled by the operator, Bond concludes. ME Jim Lorincz Wire, Die Sinking EDM CUT 2000 AWC wire EDM with an automatic wire changer allows operators to easily switch between different wire diameter sizes and types, optimizing both roughing and finishing operations and reducing production costs. The CUT 2000 AWC employs universal wire guide system, enabling it to accommodate wires from to 0.010" ( mm) for micromachining and precision applications, as well as untended production. Drill 300 machines holes in various diameters and materials, including Inconel, titanium, steel, and carbide. Electrodes range from to 0.12" ( mm) diameter. Six-axis configuration makes it possible to drill round and shaped cooling holes in aerospace blades and vanes, while the indexing table allows production of holes in a circular pattern. GF Agie Charmilles Ph: Web site: North American EDM Debut The new Fanuc Wire EDM power supply that makes it possible to produce parts with virtually no recast will be demonstrated. The Fanuc RoboCut-CiA Series including the C400iA and C600iA Wire EDMs will be under power and cutting at IMTS, where the machines are making their North American debut. The new EDMs feature upgrades including the new Fanuc 31iWB Control which features improved accuracy and finish, especially in high-taper, four-axis cutting. Live applications include examples of multiaxis cutting with fully integrated single and dual-axis rotary tables as well as complex threading. Rotary PCD tools and Fanuc s exclusive PCDEdge programming software will also be on display. High taper, soft wire cutting applications will demonstrate new Fanuc software and soft wire threading capabilities. Methods Machine Tools Inc. Ph: Web site: Three-Five Axis Wire EDMs EZ-53SA threeaxis CNC wire model features " ( mm) X-Y-Z work envelope, AWT (Automatic Wire Threader), and advanced Windows-based CE control for most jobs a shop encounters on a daily basis. The IMTS machine will have an optional fourth-axis indexing capability. The SP-300iA five-axis CNC wire EDM features the latest Microsparking Technology MST-II function that provides low recast and fine finishes required for aerospace and medical applications. The X-Y-Z working range is " ( mm). U and V axes are both 3.15" (80 mm). The axes are driven by closed-loop AC servomotors with " ( mm) resolution and controlled by a linear glass scale feedback system. AccuteX EDM, Div. Absolute Machine Tools Ph: Web site: Small Hole EDM SY Series high-speed CNC EDM machines for small hole drilling feature automatic depth control, Ethernet connectivity/usb support for programming, linear glass scales, and conversational G and M codes. The SY-1210TGU has a tilting drill head with ±100 of rotation. X-Y and W travels are ManufacturingEngineeringMedia.com August 2012

5 39.3" ( mm) and open height is 42.5" (1079 mm). Six coordinate systems allow up to six individual jobs to be programmed and run consecutively in a single setup. Maximum workpiece weight is 5500 lb (2495 kg). Optional electrode and guide changers make the drill well-suited for large tools, aerospace, power generation, and production applications. The machine can interface with ancillary devices like rotary tables, indexers, and workpiece handling systems. Belmont Equipment & Technologies Ph: Web site: EDM Machines, Consumables Mitsubishi lines of wire EDM, sinker EDM, EDM drill, and consumable products will be showcased along with the newest MV Wire EDM machine technology. The Consumable Products Group (CPG) will feature its extensive line of OEM quality consumables. Products maximize efficiencies and increase EDM machine s longevity. The product line includes filters, brass wire, zinc-coated wire, diffusion-annealed wire, power-feed contacts, and power-feed conversion kits. MC Machinery Systems Inc. Ph: Web site: Advanced EDM Technology Innovative linear motor-driven machines, new seven-year warranty programs, and consumables will be featured. Five wire EDMs and three sinker EDM models will be shown. The AP250L will demonstrate cutting small intricate precision parts with 0.001" (0.03-mm) micro wire in oil dielectric using Eco-Cut O technology 25% faster than previous oil models. All WEDMs are linear motor-driven, offer precision machining with speed and accuracy and 10-year positioning accuracy guarantee. The AG400L is ideal for small-to-medium sized parts and molds that require close tolerances and fine surface finishes. The AD25L compact sinker EDM offers high-speed, linear motor-driven small footprint EDM. The AG60L sinker EDM will be displayed with robot automation. The large capacity AG80L linear motor sinker EDM is well-suited for medium-to-large sized aerospace, energyrelated parts, and die/molds that require close tolerances. Sodick Inc. Ph: Web site: August 2012 ManufacturingEngineeringMedia.com 183

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