Product category:
EDM wire cutting
News Release from: Agie Charmilles | Subject: Twin-wire EDM machines
Edited by the Manufacturingtalk Editorial
Team on 30 July 2007
Twin-wire EDM cuts machining time by 40%
To manufacture a punch using a single 0.1mm wire EDM took 3h 12 min while a twin 0.1mm wire EDM did the same job in 1h 26 min - a saving of 40% in manufacturing time.
The trend towards wire-EDM machining micro forms and features to high accuracy on components and parts has resulted in the use of small diameter wires Small diameter wires achieve achieve the required precision, geometry and surface finish on such intricate forms
This article was originally published on Manufacturingtalk on 17 May 2001 at 8.00am (UK)
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Unfortunately, small diameter wires reduce the machining and metal removal rates.
To reduce cycle times, GF AgieCharmilles has developed twin-wire EDM machines (models FI 2050 TW and 6050 TW), equipped with automatic wire change to give high precision and high productivity.
** Twin-wire EDM operation - EDM machining speed during roughing operations is directly related to the strength of the current passed through the wire.
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Therefore roughing speed is proportional to the diameter of the wire used - the larger the diameter of the wire, the greater the speed.
The twin-wire machines exploit this principle by using large diameter wires for roughing cuts.
The GF AgieCharmilles' twin-wire machines use different diameter wire - including wire down to 0.05mm - to achieve accuracy and finish.
The large and fine diameter wires can be used interchangeably, in cycle, and without operator intervention.
The result is as follows.
* Higher productivity and manufacturing flexibility.
* Increased work throughput.
* Elimination of stop-start operations.
The machines can also use wire with identical diameters, but with different grades, for roughing and finishing.
It means that users can reduce wire costs by up to 30%.
** Twin-wire EDMs - twin-wire machines have a rugged construction that includes cast iron Vee/flat guides and are equipped with a high-performance CleanCut generator.
The machines deliver cutting speeds in excess of 400mm2/min and 0.2 micron Ra surface finish.
Glass scales, providing 0.05 micron resolution, are used on the machines to ensure accuracy and a novel cooling system reduces thermal distortion on all structural and mechanical elements.
The machines have two front-mounted and one rear-mounted wire magazines which can accommodate DIN or JIS standard spools.
The front-mounted magazines accommodate spools up to 8kg.
The rear-mounted magazine accommodates spools 16kg - 25kg.
These twin-wire EDM configurations allow users to benefit from long uninterrupted machining - including 'lights-out' and weekend working.
Wires are separately guided from the magazines.
All wire handling components such as balance arms, encoders and brakes are duplicated enabling independent and automatic adjustment for each wire used.
Wires are prepared and are held in readiness above the machining zone for immediate access.
The changeover between wires occurs automatically and takes 1s.
The machines have a single closed guidance system - the guide being the same diameter as the largest wire and a Vee-guide.
Twin wire machines automatically compensate for the difference in wire diameter, once a change has been made, ensuring that the wires are always centred.
Twin-wire machines are simple to program and the operator only needs to input basic data - workpiece height; surface requirement, wire used, etc.
The machine's EXPERT system generates the program and manages the wire change automatically.
Threading reliability is enhanced with the ThermoCut facility.
This system along with an automatic hole seeking cycle optimises wire threading - even for minute holes.
Said Peter Pearce, GF AgieCharmilles EDM product specialist: "The benefits from using twin-wire EDM machines are staggering.
For example - to manufacture a punch using just a single wire (0.1mm diameter) took 3h 12 min.
When we used the twin-wire machine - using 0.25mm diameter wire for the roughing cut and 0.1mm diameter wire for the finishing cut - the time taken to manufacture the punch was 1h 26 min - a saving of 40%.".
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