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IMTS PAVILION: EDM


wire EDM software, these inspection capabilities are critical for meeting quality and part production targets, Ledvon said. “There’s still a problem with fi nding skilled operators in these processes. You want that part to come off the machine per- fect, so you’re really relying 100% on the machine.” By automating the process, the wire EDM ma- chine can cut many openings in a high-precision die and the system takes a picture with the video or optical system and compares the CAD fi le, Ledvon said. “It looks at all the radii—and we’re talking one or two microns—and it cuts right on the money,” he said. Another big trend on the diesinking side is adjusting and refi ning the time taken in the cut for moldmakers, he added. GF Machining developed a 3DS mold texturing feature that adjusts the spark, Ledvon added. The development was done in con- junction with a moldmaking company in Germany, which uses it in its own injection molding presses. “This helps moldmakers adjust the time of the cut and reduce the fl ow time into the mold, which is important when you have very small details.


“The 3DS is a combination of things,” Ledvon said. “It’s a


software feature in the CNC control and a new generator to create this spark pattern.”


At IMTS, GF Machining will also show for the fi rst time its new Cut 200 wire EDM system that Ledvon said is dedicated for aerospace industry use. This wire EDM system helps manufacturers who are producing fi r-tree-shaped disk com- ponents to eliminate broaching on the parts, which are used in jet aircraft engines.


Improving Effi ciency, Cutting Costs Among EDM technical trends, boosting operator effi ciency is key as customers from all sectors of the market struggle to fi nd experienced machine operators, noted Brian Pfl uger, EDM product line manager, Makino Inc. (Mason, OH). “End users are forced to home-grow their own operators, and this training process often results in lost production or scrapped parts,” said Pfl uger. “To address this growing issue, Makino has de- veloped the Hyper-i control, which provides the same interface and operating methodology for both sinker and wire EDM.” The Makino Hyper-i control features a very familiar smart- phone or tablet-like graphical touch interface that streamlines the machine learning curve and improves machine productiv- ity, Pfl uger said. “The Hyper-i control also contains its own


142 AdvancedManufacturing.org | August 2016


on-board training system that includes video tutorials. The machine manuals have also been digitally integrated into the machine control, providing operators of all skillsets with the in- formation they need to be productive and effi cient,” he added.


The entire line of Makino EDM machines at IMTS will feature a standardized Hyper-i EDM control interface.


Operational cost reductions also are an aspect EDM customers are very aware of and they are interested in methods of reducing their manufacturing costs, Pfl uger said. “For wire EDM operations, this relates to the amount of wire that is consumed for a particular job. The wire consumption value for a wire EDM machine is like the fuel economy of a car—the less wire that is consumed, the lower the manufac- turing costs will be,” he said. Makino created its wire EDM cutting technology database for all materials and wire sizes to achieve the best operational effi ciency, he noted. Similarly, with sinker EDM operations, the number of elec-


trodes required to produce a fi nal part is the main cost factor in machine operation, he added, and Makino has developed new technologies that minimize wear on the electrode. “These wear factors can be below 0.1%. This low electrode wear technology provides the ability to rough and fi nish a complete job using a single electrode process,” Pfl uger said. “The total manufacturing costs are reduced by minimizing the number of electrodes, electrode material, and milling prepa- ration of the electrodes required to produce the fi nal part.” Machine connectivity also is a key component, as cus-


tomers are starting to focus on factors including machine uti- lization and adapting a “work smarter, not harder” mentality, Pfl uger added. At IMTS, Makino will showcase several differ- ent methods for improving productivity, Pfl uger said, includ- ing automation in its sinker and EDM lines, a standardized Hyper-i EDM Control Interface on all Makino EDM machines,


Image courtesy Makino


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