Product category:
Micro- and nano-machining
News Release from: Hirschmann Engineering UK | Subject: Wire EDM turning small parts
Edited by the Manufacturingtalk Editorial
Team on 10 September 2007
High speed spindle wire-EDM turns small
parts
A high speed rotary spindle allows extremely small parts - down a diameter of 10m - to be cut accurately and cost effectively using EDM wire erosion for turning.
Hirschmann is introducing a second generation of its high speed rotary spindle (H80R.MAC), which allows even extremely small parts Sizes can be down to a diameter of 10 micron - to be cut accurately and cost effectively
This article was originally published on Manufacturingtalk on 18 Aug 2005 at 8.00am (UK)
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The technically advanced spindle, which was launched with great success two years ago, was developed specifically to permit even very small parts to be turned on an EDM wire erosion machine.
It has met with market acclaim throughout the Western engineering industry ever since its launch: ideally suited for manufacturing parts for the medical, sensory analysis, fluids and automotive industries, its application is already widespread throughout the world of micro machining.
The new generation of the H80R spindle enjoys the same specification as the original H80 spindle but has the additional benefits of positional indexing and servo controlled erosion using the rotary axis.
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This is in response to requests from, in particular, the medical, micro technology and aerospace industries to combine EDM turning of small parts with indexing and servo controlled erosion.
The new rotating and indexing spindle allows parts to be EDM turned or EDM ground with a plane cut at different angles.
It can be used with a System 5000 pneumatic clamper to enable automatic loading, so can be employed in a fully automated production system as easily as in stand alone EDM machines.
Hirschmann developed the high speed rotary spindle (H80R.MAC) in response to a clear industry need to cut extremely small parts - down a diameter of 10 micron - accurately and cost effectively.
Using the high speed rotary spindle, a conventional WEDM machine becomes an EDM turning or grinding machine.
Difficult or complex shapes or very small parts, which would have required several production processes, can now be turned simply on a wire erosion machine.
The spindle was developed and tested in conjunction with the Institute of Micro Technology in Mainz, Germany.
It is suitable for high speed applications.
Parts which have traditionally been both difficult and expensive to manufacture can be produced cost-effectively without compromising accuracy.
Dental drills, medical implants and instruments, minimised assembly groups, micro moulds for plastic injection and micro tools can be manufactured more economically and without the traditional problems associated with the form/cylindrical grinding of small detailed parts.
The Hirschmann H80R spindle is easy to set up and use, considerably improves productivity and significantly reduces production costs when compared with grinding.
The use of the high speed rotation on a standard Wire EDM machine facilitates the highest profile quality and surface finish as it eliminates the wear associated with the use of a traditional grinding wheel.
Used with the newly patented Hirschmann adjustable collet, the high speed rotary spindle provides the highest axial accuracy at rotary speeds of up to 1500 rev/min.
The spindle can also be interfaced with the EDM controller to offer improved autonomy.
Component surface finish and geometry are comparable with traditional grinding techniques.
The added benefits of simple set up and easy 2D programming lead to faster production times coupled with reliable reproduction reducing scrap.
The Hirschmann H80R rotating spindle provides a viable and economic alternative to grinding small components.
Grinding induces large forces onto the component: in small components this can cause movement or - more likely with micro machining - breakage.
Form grinding also requires a number of wheels to be produced creating high manufacturing costs due to time and effort and the production of complex geometries with small radii is virtually impossible.
Free from lateral side forces, geometries can be created without the influences of grinding wheel wear and form error.
By rotating the component accurately at high speed the surface is comparable with that of grinding.
Set up is much faster using the high speed rotary spindle than with grinding.
Metal removal rates are also improved when compared with grinding.
* Hirschmann at EMO 2007, Hannover, Germany, September 17-22, Hall 25, Stand H30.
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