EWS made EDM Wire Cable e40

Transcription

1 EWS made EDM Wire Cable e40 Made in Japan Why is e40 wire so popular? Made in Japan Total manufacturing (Melting to shipment) High quality Competitive price Quick action Japan

2 Total Manufacturing for Tool & Die Die Sinking EDM Wire-EDM Small Hole Drilling EDM High speed Machining Center Injection Molding Machine

3 Core Technology of Sodick Sodick develops & manufacturers all core technology in house.

4 Sodick manufactures Wire electrode used for W-EDM *Sodick has many group companies. One of them manufactures Wire electrode. * Wire electrode holds key for EDMing quality. * With an EDM experience of many years, Sodick started manufacturing wire electrode and can utilize a vast knowhow stored in developing, designing and manufacturing EDM during the past many years. * Sodick is the only manufacturer in Japan who manufactures wire from A to Z. (Others purchase wire strand and draw wire into the size.)

5 How is Sodick EWS Different from Others? (1) Wire Electrode Manufacturing in General Material Melting Wire Strand Wire Drawing Wire Inspection Packing Shipping Wire strand supplier A Wire electrode manufacturer B (2) Sodick EWS A + B = Responsible wire electrode manufacturer Material Melting Wire Strand Wire Drawing Wire Inspection Packing Shipping Sodick EWS (with facility + EDM experience)

6 Why is Total Manufacturing Required in One Factory? Sodick EWS manufactures wire electrode from fusion to finished wires in-house. Sodick projected from beginning to have a complete production line for the following reasons. Reasons: 1.Sodick can improve quality by adjusting raw material percentage. 2.Better quality can be achieved and maintained easily (This process needs a long experience in EDM development, manufacturing and operation. 3.Can reduce cost. 4.Sodick can hold responsibility for product (quality control for each process and operation efficiency) and also shorten delivery Details are in next pages!

7 Complete Quality Control Raw materials are melted Impurities are disposed of Material inspection Impurities are disposed of Draw die Auto traverse Wire drawing Annealing Wound on bobbin All products are Inspected. Data are stored.

8 Quality Control ( Melting) *This process is to make Φ8.0mm wire strand by melting Pure copper & pure Zinc. *For high quality brass, componential analysis are performed in every fusion process. Manufacturing Process 1Material 2Fusion 3Hardening 4Φ8.0 Primary Wire Inspection Inspection Removal of lye Analysis of ingredient [Shimazu EDX720] Brass Inspection Every single fusion process is inspected Removal of second lye Surface observation Crack Oxidization

9 Quality Control ( Wire strand ) The wire of Φ8.0mm is drawn to Φ3.0mm and further drawn to Φ0.9mm diameter wire After machine oxidizes wire surface, Φ8.0mm is drawn to secondary Φ3.0mm Manufacturing 5Φ8.0mmWire 6 7Φ3.0mmWire Process 8 Inspection 9Finish the Φ0.9mmWire Tension test by tension tester

10 Quality Control (Wire drawing) *Φ0.9mm diameter wire is drawn to.07,φ0.10,φ0.15,φ0.20,φ0.25,φ0.30 *Through this process, diameter, tensile strength and elongation are determined Manufacturing Process 9 Set Φ0.9mm Wire strand 10 HMA-21J Wire drawing machine draws wire to required diameter. Drawing process portion. Use wired dies to decrease diameter. Set appropriate wire dies 12 Wire winding unit. Automatic traverse equipment. 12 Finished product

11 Quality Control (Wire drawing) Each product is carefully inspected for wire diameter, weight, curl, tensile strength,and also visually inspected. * Moreover, the product data is stored in software developed in-house. All products are inspected and its data is stored. Manufacturing Process Curl inspection Wire is cut in 1m and inspected for straightness. Diameter and roundness are measured by laser. Weight is measured on scale. Tensile strength is tested on tensile tester. Surface is tested by microscope to check scratch, dirt, stain, deformation, etc. Outer check to check dirt on bobbin, color change.

12 Quality Control (Packing) * Rust-proof paper is rolled around inspected product, and shrink-wrapped. * Bar-code is utilized to manage product labeling and packaging Manufacturing Process Wire products after inspection Inspection Shrinking Packaging External appearance test After checking bobbin and labeling, wires are wrapped by rust-proof paper and shrink-packed to avoid corrosion and moisture. To avoid mixed packaging Boxes and wires are managed by bar-code. Shipment

13 Power of EDM Specialized Manufacturer To produce most suitable wire for EDM, wire is annealed to have satisfactory tensile strength and elongation. The wire is evaluated in application sector in Sodick group company. Application room in group company Anneal unit inside wire drawing

14 Main Product of Sodick EWS It is a hard wire with major components of Copper 60% and Zinc 40%

15 Interchangeable Table by Element of Wire Electrode HBZ-U(N): Hitachi wire OB-PZN & OB-OZ: Oki wire CTW(TH) & CTW(TH)S: Chiba Techno SBG: Sumitomo wire

16 Wire Selection of e35/e40 for Each EDM Model

17 Wire Surface Comparison * A comparison was made for surface roughness between another Japan-made wire and Sodick EWS wire. The result is as below. You can see different roughness.

18 Where does Sodick EWS stand in Quality & Price? High quality High price

19 Production & Market Shares in Japan

20 Super Manufacturing Award in Japan * In October, 2009, the wire of Sodick EWS was granted the Super manufacturing Award for the high quality wire electrode selected by the Japan Industrial Newspaper company. for the reason below: * High quality of product through Quality Control at all stages. * The below shows the scene of award presentation.

21 Where is Sodick EWS? Land area :33,000 m2 Average salary Factory :6,000 m2 Osaka Staff number: 50 60% Tokyo Miyazaki Japan Miyazaki prefecture Tokyo prefecture

22 EWS made EDM Wire Cable e40 We thank you for your support Japan