Behind every great tool there’s a great idea The tool:
KOMET KomTronic® U-Axis system Modular mechatronic conversion unit
EDM Technology
GF AgieCharmilles’ Intelligent Power Generation (IPG) generator provides precise spark control for the EDM drilling machines with different parameter settings for the various stages of the drilling process and according to where the electrode is in the hole. “It is this functionality that also helps reduce electrode wear, which, in turn, allows for deeper drilling, increased speed and accuracy and higher surface-finish quality,” said Baeszler.
The idea:
Expanding the capabilities of standard machine tools.
Why it’s great: • Provides an additional axis, allowing for complete machining of complex parts on a single standard machine tool.
• High accuracy for internal and external contours, and parts which are not rotationally symmetrical.
• Same system can be used on several machines and for diverse machining operations.
Learn more about this and other great ideas.
Go to
www.komet.com/greatideas or scan this QR code.
Spark control is accomplished via software in the digital generator that modifies or adjusts spark behavior as the electrode enters a hole and when it exits—a func- tion often referred to as entrance and breakthrough protection. “These protection functions, such as our Intelligent Breakthrough Detection, prevent instability dur- ing hole exiting, shorten actual electrode exiting time, eliminate back-wall striking and help maintain hole diameter size at the point of exit. The function also calculates the nec- essary electrode retract length so that it can be safely moved to the next hole, as well as how much of the
Current EDM Model RT6050-5AT EDM drilling machine from Methods Machine Tools features a powerful, multiaxis Siemens 840D CNC controller for greater expandability and industrial level security. Software and hardware upgrades to the controller and EDM power supply improve drilling speed and stability, while reducing electrode usage and improving metallurgical “recast’ issues.
electrode is left and if that remaining amount is enough to do the next hole or if an automatic electrode change should be initiated,” said Baeszler. These capabilities are what allow modern EDM drilling systems to accurately, effi- ciently and automatically process those workpieces involving multihole and/or multielec- trode size operations. In the case of a conventional hole popper, the operator—a highly skilled one is required—would have to perform all of these functions. “For increased EDM drilling productivity, the goal is to generate as many holes as possible or drill as deep as required using the least amount of electrodes. The more a generator can help reduce electrode wear, the better. Plus, less wear on electrodes allows them to cut faster and more accurately by eliminating ‘bullet nosing’ of their tips,” said Baeszler.
TOOLS PLUS IDEAS
www.komet.com
800-656-6381 82
ManufacturingEngineeringMedia.com | November 2013
Lab Testing Confirms Small-Hole EDM Drilling Results To illustrate, a conventional popper system using a 0.040" diameter electrode to drill through about 3.937" (100 mm) of hardened steel, would typically experience 100–150% of electrode wear. However, in lab testing, GF AgieCharmilles accom-
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