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Hybrid combines wire EDM and waterjet cutting

Edited by the Manufacturingtalk editorial team Nov 14, 2006

A linear motor powered hybrid wire EDM machine combines the precision of wire EDM with the high-speed waterjet cutting process to dramatically improve productivity.

At IMTS in Chicago, Sodick launched its radical new linear-motor driven Hybrid Wire EDM machine - a product which offers dramatically improved productivity by combining the ultra-high precision of wire EDM with the high-speed machining of waterjet cutting.

Traditionally, Wire EDM cutting speeds have not been able to exceed 1270mm2/h.

This is a statistic, which all EDM manufacturers have been striving to improve upon, as increasing numbers of wire EDM users express the need for faster cutting speeds, higher accuracy and improved quality.

In response to this challenge Sodick has developed the newly-launched, Hybrid Wire EDM solution, in order to facilitate the development of which a partnership has been created with the world's largest waterjet manufacturer, Flow International Corporation.

Benefits of the Hybrid Wire machine include the following.

* The unique feature of Sodick's Hybrid Wire EDM is its ultra high speed cutting - graphite material, which is traditionally cut by Wire EDM, can be cut up to 20 times faster than Wire EDM for the first rough cut which is 10150mm2 /minute (approx.

203mm/min for 50mm thickness).

The standard material for mould and die is D2 (52 HRC) which can be cut at 14100mm2/minute (94mm/min for 150mm thickness) * Initial hole-cutting and disposal of core for press mould are performed ready for automated operation - initial hole-cutting, which previously needed to be carried out on a separate machine, can be performed on the Hybrid Wire EDM.

Furthermore, the core, produced during transfer-press manufacturing, drops naturally, which also helps achieve automated operation.

In short, once a hardened steel plate is set on a Hybrid Wire EDM, all the machining from initial hole-cutting, core handling and finishing can be performed automatically without operator intervention.

* Flexibility: waterjet cutting, wire cutting or combined cutting can be selected - the waterjet-only functions can be used for ultra-high-speed cutting, even for insulated materials, while ultra-high-precision and thick material can be cut by the Wire EDM functions.

Ultra-high-speed cutting by waterjet and finishing by Wire EDM machining, offers increased flexibility for many applications.

* Reduced space requirement - traditionally, two separate machines have been required for waterjet cutting and wire cutting - taking up valuable floor space.

The Hybrid Wire EDM solution eliminates this problem with just one small footprint machine.

* Environmentally-friendly process - both the waterjet cutting and wire cutting processes use water fluid in the Hybrid Wire EDM machine, thus ensuring graphite chips do not become airborne.

With this revolutionary new wire EDM solution, Sodick is confident that the demand for electrical machining will continue to increase, as it will satisfy both high-speed and high-precision production, and in so doing help re-shape manufacturing processes.

Following the Hybrid Wire EDM launch at IMTS 2006 show Sodick will be ready to receive orders for the machine at the end of this year and expects initial production to be 5 units per month, increasing to 10 units per month according to market demand.

* Machine Specification - wire portion - is as follows.

Travel (X-, Y-, Z-axis) (mm) - 559 x 355 x 254.

U-,V-axis (mm) - 569 x 368.

Taper cutting (for 150mm) - 30 deg.

Wire electrode diameter (mm) - 1.524-0.305.

Maximum wire spool - 20kg.

Maximum wire feed speed - 400mm /sec.

* Waterjet is as follows.

Travel(X, Y, Z axis) (mm) - 584 x 381 x 254.

A/B axis control angle - +/-10 deg.

High pressure flushing power - 380Mpa.

* Hybrid Wire is as follows.