Product category:
EDM wire cutting
News Release from: Agie Charmilles | Subject: Twin-Wire EDM technology
Edited by the Manufacturingtalk Editorial
Team on 10 August 2006
Twin wire EDM improves part accuracy,
finish
In just under three months a twin wire EDM has had a dramatic impact on a company's performance and productivity - providing improved part accuracy and superior surface finish.
DR Case and Sons said that being the first UK manufacturer to invest in the latest twin-wire EDM technology from Charmilles will further strengthen its position as one of the UK's Number One wire EDM specialist subcontractors Brighton-based precision wire EDM specialist subcontractor - DR Case and Sons - has recently made a significant investment in Charmilles' latest Twin-Wire (TW) EDM technology
This article was originally published on Manufacturingtalk on 17 May 2001 at 8.00am (UK)
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The machine, a Robofil 6050 TW, was installed at DR Case's facility in July 2005 and is the first 6050 TW machine to be installed anywhere in the UK.
In just under three months the machine is already having a dramatic impact on the company's performance and productivity - and in particular is providing DR Case with additional manufacturing capabilities and flexibility plus improved part accuracy and superior surface finish.
The machine has enabled DR Case to further streamline its manufacturing and production planning and work scheduling - allowing it to improve its productivity by achieving more efficient machine utilisation and extending its utilisation of 'lights-out' unattended operations.
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These in turn have helped the company reduce its manufacturing lead times, reduce the cost per part and improve its overall competitiveness.
The benefits of twin wire technology in terms of optimising roughing and finishing machining operations by using different diameter wires is well documented and is a key feature of the new 6050 TW machine.
The machine has automatic wire change capability and is equipped with a two 8kg wire spool capacity situated at the front of the machine and one 16-25 kg wire spool capacity at the rear.
This configuration provides the company with significant manufacturing flexibility and extended machining capability - which it employs to the full through lights-out unattended operations and weekend working.
Every month the company takes on a huge variety of work from a number of different customers - this could, on the one hand, include manufacturing high- precision tungsten components for new, state-of-the-art oncology detection and treatment equipment and on the other manufacturing complex press tools and progression dies for use in the electronics sector.
Because the work is so varied - the company decided to invest in the larger 6050 TW machine instead of the smaller 2050 TW option.
This means that the company can take advantage of the machine's X, Y, Z travels of 628 x 398 x 160mm and its ability to handle workpieces up to 1260 x 610 x 360mm in size and a maximum weight of 800kg.
Because time is always of the essence the company's productivity has also been enhanced by the machines' fully automated tank doors and the ability to gain full access to the working area without having to wait for the tank to drain.
As well as increased productivity other major benefits of the 6050 TW machine are its ability to provide DR Case with guaranteed high-precision and superior surface finish.
Owing to the machine's robust and rigid construction and cast iron V/flat guides - the 6050 TW guarantees life time accuracy and optimum performance.
The machine, generator and control are all fully-integrated and are positioned on a pallet thereby providing greater equilibrium and improved weight distribution which in turn results in greater part accuracy, repeatability and finish.
The machines are equipped with the tried and tested CleanCut generator - already available on Charmilles' highly-popular 240/440/640 CleanCut machines.
The CleanCut generator ensures high cutting speeds, excellent accuracy and finish - and, especially important for precision component manufacture in the aerospace and medical sectors - virtually eliminates the creation of the re-cast layer and maintains excellent surface integrity of the machined material.
As well as through the generator - accuracy is further optimised by the machines' glass scales, which can provide a resolution of 0.05 micron and by a unique cooling system that reduces thermal distortion on all structural and mechanical elements of the machine - (column, base, cross table, scales, tank and frame).
Said Colin Case, director at DR Case: "We are very happy with our new Charmilles machine and we have high hopes for it in the future.
As a precision wire EDM subcontractor we need to not only continuously invest in the latest technologies to maintain our competitive edge we also have to make such investments at the right time." He added: "Although the 6050 TW machine has only recently been launched we knew that having it sooner rather than later would give us a distinct advantage over our competitors who might make a similar investment later down the line." ' Case said: "The fact that we have secured new business as a consequence of purchasing the 6050 TW early vindicates our investment decision." * About DR Case and Sons - DR Case and Sons is a small company with big ambitions - many of them already realised.
The company specialises in the manufacture of high-precision, complex parts, components, mould tools and progression dies for a wide-range of customers across an equally diverse range of industry sectors (medical, F1, aerospace, general engineering, etc).
The company's ability to win, and to continue to win, regular and high-added value wire EDM subcontract work is testament to DR Case's skill, commitment and strategic investment in the very latest advanced EDM technology.
This commitment to continuous improvement, has over recent years, seen the company continually upgrade its technology and make significant investment in Charmilles wire EDM machines.
Today the company not only has the new 6050 Twin Wire machine - it also has a Robofil 2020 SI, a Robofil 4020 SI, a Robofil 330F, a Robofil 100 and a HD 10 (EDM hole drill machine).
Other machine tool investments and upgrades are 'in the pipeline' too.
Amongst these is the company's determination to integrate remote monitoring into its manufacturing processes to provide greater control over unattended and over night operations.
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