Product category:
EDM wire cutting
News Release from: Sodi-Tech edm | Subject: Wire EDM machine tools
Edited by the Manufacturingtalk Editorial
Team on 15 June 2007
Wire EDM cycle times reduced by 25%
In selecting new wire-EDM machine tools, a UK mould tool maker devised a complex workpiece, on which speed, accuracy and surface finish were judged; the EDMs purchesed reduce cycle times 25%.
A rapidly expanding plastics injection mould tool manufacturer is using two high specification Sodick wire EDM machines featuring linear drives to cut cycle times by 25% and compete not just with other UK competitors but also with overseas rivals Established in 1988, Ryetools has become expert in the design and manufacture of complex plastics injection mould tools up to 4 tonnes capacity
This article was originally published on Manufacturingtalk on 27 Sep 2005 at 8.00am (UK)
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Industries served are wide ranging but principal ones include medical, pharmaceutical, packaging, automotive, defence and electronics.
Based in Pickering, North Yorkshire the firm today employs 15 people and is set to move to a brand new, purpose-built facility that is three times larger than its existing premises.
An ambitious investment policy drives the toolmaker's growth, the latest results of which are a Sodick AQ325L wire EDM with linear drives, and the larger AQ535L, both of which were supplied by Sodi-Tech EDM.
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The machines work in tandem with an existing Sodick K1C high speed hole EDM.
"We bought the machines purely because we needed extra wire EDM capacity," stated managing director Darren Hugill.
"We prepared a complex test piece and offered it to four suppliers, including Sodi-Tech EDM.
We selected the AQ linear machines because they were faster, more accurate and provided a better surface finish.
Additionally, we've been running an older Sodick wire EDM (A320D) for 12 years and it has been an excellent machine in terms of performance and reliability." Sodick's linear motor technology provides instantaneous servo time, which maximises cutting efficiency.
Since there are no ball screws or couplings, backlash is totally eliminated, which offers several advantages.
These include improved positioning and cutting accuracy while at the same time providing smooth and vibration-free table movement.
Hugill said that since installation the two Sodick AQL machines have been performing reliably without any problems.
"We work the machines hard," he added.
"They run all day and are left to operate unattended during the night and at weekends whenever possible." Prior to the latest Sodick machines being installed, components manufactured by Ryetools would be wire eroded adequately using the company's existing Sodick A320D.
In comparison, however, cycle times using the linear machines are proving significant enough to more than justify the capital expenditure and maximise return on investment.
"On average our wire erosion cycle times have reduced by approximately 25% thanks to the introduction of the two Sodick linear machines," explained Hugill.
"The linear motors also mean that we can achieve greater accuracy.
Overall I am very satisfied with our investment.
Acquiring the latest technology is absolutely crucial to our competitiveness, particularly with regard to competition from Eastern Europe and the Far East.
The only way to combat this is to increase productivity, a factor on which the two Sodick linear EDMs have had a significant impact." At present the two AQL machines and the older A320D are overseen by a single operator at Ryetools who is responsible for programming, setting and inspection.
Overnight, machines run 'lights-out'.
Progressive manufacturing strategies such as these are ensuring mould and toolmakers like Ryetools prosper in what has become a notoriously testing marketplace.
To heighten its chances of growth the company focuses on high specification, complex injection moulds.
"If a mould tool has to produce millions of parts (without flash) over its lifetime and the cycle times required are exceptionally fast, then we believe we can offer the expertise, technology and quality to meet these demands," said Hugill.
"Talking to our customers, many tools sourced from mouldmakers based in low cost economies are not of sufficient quality to handle exceptionally fast cycle times." The additional quality at Ryetools is provided in part by the two Sodick AQ linear wire EDMs, which complement the company's other manufacturing capabilities that include milling, turning, grinding and spark erosion, as well as extensive CAD/CAM know-how.
"Quality is consistently achieved through all staff applying an 'attention to detail' philosophy to each stage of manufacture - from 3D CAD design, job planning and monitoring through to CNC manufacture, assembly, full tool trial, inspection and tool handover," said Hugill.
"Our pricing structure and investments in CNC machinery and software (and the people to efficiently operate them) means that, on a like-for-like basis, our prices remain really competitive." It's a successful policy that is helping facilitate the company's impending move to new headquarters, which in turn reflects Ryetools' determination to survive and compete at the top end of the market.
"We've seen some UK competitors go out of business, and we have seen UK customers return here after placing work overseas due to issues such as quality, delivery and confidentiality," concluded Hugill.
"We have to ensure we are best placed to maximise our gains in situations such as these, a task in which our Sodick linear EDMs have a big part to play.".
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