Product category:
EDM diesinking
News Release from: Agie Charmilles | Subject: High speed die-sink EDM - Roboform 350/550
Edited by the Manufacturingtalk Editorial
Team on 05 June 2007
High speed die-sink EDM offers speed and
quality
High-speed die-sinking EDM machines, intended for machining pre-roughed 3D cavities and complex parts with deep rib features, offer speed, responsiveness and very fine surface finish.
Charmilles' new 'High-Speed' Roboform 350/550 die-sinkinking EDM machines reduce cycle times in producing complex parts without compromising on part quality and surface finish A member of the Swiss GF AgieCharmilles, Georg Fischer Group, EDM machine tool company Charmilles has launched a range of high-speed spark erosion machines into the UK
This article was originally published on Manufacturingtalk on 17 May 2001 at 8.00am (UK)
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The machines - the Roboform 350/550S - are aimed at the machining of pre-roughed 3D cavities and complex parts with deep rib features.
The machines offer speed, responsiveness and ability to deliver 'super-fine' and homogeneous surface finishes ( below 0.4 micron Ra) on complex parts.
Charmilles product specialist, Peter Pearce, said: "Manufacturers operating in globally-competitive markets need to be able to meet stringent lead times and achieve consistently-high part quality and accuracy.
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To do this they need new technology that helps reduce part cycle times without compromising on quality.
The new Roboform 350/550S machines have been designed to do just that." The Roboform machines are equipped with a fast Z-axis (7.5m/min) - twice as fast as the Z-axis movement on earlier 350/550 models.
The machines can achieve acceleration rates of 5m/s2 - an improvement of 500% on previous machines.
In 'benchmarking' trials using a graphite electrode to machine a 70mm deep cut in a steel workpiece - the Roboform machines achieved the desired result in just 2h 24 min - 25% faster than on other EDM machines.
In addition to their fast Z-axis speeds and impressive acceleration - the machines' fast pulsation speeds help improve evacuation of debris/particles located in the spark gap (critical when machining deep ribs, cavities etc.).
Fast pulsation, in turn, also helps optimise the EDM machining process in terms of faster stock removal rates, improved surface finish and increased electrode life.
Productivity and performance benefits are further ensured when the 'Speed Finishing' settings are selected on the machines.
Irrespective of the dimensions of surface to be machined (large or small), precise and delicate features can be reproduced to exacting standards with significantly reduced less electrode wear.
An integrated high-performance micro-fin generator unit connected to the machining head is the reason.
This technology configuration - plus advanced adaptive software - enables the machine to monitor and predict cutting conditions that exist/that are likely to exist in the spark gap.
The technology processes the information quickly and enables the machine to respond in real time to the changing conditions.
This facility means that the required results in terms of accuracy, surface finish, removal rates, etc, are not affected or compromised.
In trials using the 'Speed Finishing' settings - a surface finish of 0.5 micron Ra was achieved in 6h in a 60cm x 60cm x 0.5cm cavity.
With other EDM machines a similar result was achieved in 18h.
The Roboform machines are equipped with the latest DPControl system (Version 2.1).
This powerful control system is operator friendly and is simple to use.
To save time and reduce potential programming errors or omissions - new features and functionalities have been incorporated.
For example in the 'EDM Preparation' menu - additional 'prompt' screens enable the operator to customise and fine-tune the machine to match the job requirements, such as the following.
1 - Being able to define specific surface geometry (circular, rectangular) of the part.
2 - Being able to specify between helical cylindrical and helical conical, etc.
Continued Pearce: "The 350/550S machines are fast but this is not just a consequence of increasing Z-axis speeds and acceleration rates.
The new machines have 'Speed Finishing' settings so that the desired surface finishes can be achieved in less time.
In many instances the need for secondary hand polishing operations are eliminated altogether, which again represents a huge time (and cost) saving.
Pearce added: "The new DPControl saves time during programming and also speeds up and makes more reliable - the whole EDM process.
And finally sophisticated E-Doc capability on the machines means that operators can access (on-line) our extensive knowledge management database to help update their skills and reduce the amount of time required for training." Pearce concluded: "All of the above add up to significant productivity and performance benefits.".
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