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Die sinking by EDM of molds - quicker, more accurately and more economically.
Production cell for the fully automatic die sinking by EDM of single and multiple component tools, multi cavity tools and hard metal dies.
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Our larger range of machines ideal for cooling hole production in blades, vanes and shrouds. Machine axis configurations ranging from a single axis to six axes using high frequency, low inertia brushless D.C motors and optical encoder feedback devices.
- Fabricated steel machine base and column
- Integral generator and control system cubicles
- Windows based operator interface
- T.P.M. software
- Signature analysis
- Remote Process Monitoring (DAX)
Control System
- Digital servo technology for both machine and EDM axes giving repeatable performance and response
- Standard part programming language using familiar M & G codes
- Windows based operator interface
- Large Hard Disk capacity for storage of part programs
- Generator programming integrated into CNC operator interface for single point of entry programming
- Distributed I/O system using INTERBUS™ technology vastly reduces machine wiring, greatly simplifies machine maintenance, and improving reliability
- IEC1131 compatible PLC programming of machine and automation using ladder statement-list and 3 other available languages. PLC may be programmed and monitored on line via external PC connected via a standard serial link and using a Windows compatible "front-end"
- Servo tuning software to maintain optimum axis performance of the EDM head
- EDM Servo parameters may be automatically updated relative to specific tooling of part programs
- Servo tuning software with graphical display available
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MACHINE UNIT FEATURE :
- CAD design and high precision structure.
- FC-30 casting made from Furan No-Bake Molding system.
- Base, Saddle, Column and Spindle are with synchronous boring to keep the highest precision.
- GRUNDFOS horizontal pump made in Denmark.
- Movement surface with TURCITE.
- X and Y axes are constructed with V-Shape and Fiast sideways.
- High precision and strength Quill assures excellwnt eroding.
- Hardness heat treatment and high precision frinding worktable assure structure precision and life.
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All Machining accuracy within ±2µm. The EDAC1 features Makino's drop tank design that is open on two sides for outstanding access. The dielectric fluid height can be adjusted to match the height of the workpiece. This makes it easy for the operator to see the machining condition even for small workpieces. Moreover the EDAC1 has the ability to execute the tiny corner radii required by precision dies/molds for making connector parts and other components.
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The EA8-M and EA12-D are characterised by best eroding results and long-term accuracy. They are fit for all areas of application, from fast roughing up to finest smoothing. With the proven generator and 64 bit control technology they satisfy highest demands in daily use for all eroding applications. User-friendlyness and flexibility are the basic principles for this. The EA8-M and the EA12-D allow the machining of almost all materials, from Carbide and Ampcoloy up to Aluminium and Steel. The AC servo drive with digital outputs achieves a 50% reduction of removing time as well as an increase of the removing rate. Removing time and eroding time are optimised by an "artificial intelligence"; the machine "learns"!
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The EA8-M and EA12-D are characterised by best eroding results and long-term accuracy. They are fit for all areas of application, from fast roughing up to finest smoothing. With the proven generator and 64 bit control technology they satisfy highest demands in daily use for all eroding applications. User-friendlyness and flexibility are the basic principles for this. The EA8-M and the EA12-D allow the machining of almost all materials, from Carbide and Ampcoloy up to Aluminium and Steel. The AC servo drive with digital outputs achieves a 50% reduction of removing time as well as an increase of the removing rate. Removing time and eroding time are optimised by an "artificial intelligence"; the machine "learns"!
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Bore holes. Cut slots. Machine shafts. All at microscopic dimensions previously impossible. The MG-ED82W micro electro discharging machine gives you high-quality micro machining of conductive materials down to dimensions as small as 5µm.
From tool-quality quenched steel and carbide to highly fragile materials such as ferrite, any conductive material is eligible. Micro-EDM provides minimized electrical discharges, almost to a negligible amount, that produces cleaner, more accurate shapes than energy beam technologies.
Our unique WEDG technology, which comes standard with our machines, allows you to profile-grind your own tool electrodes on the same machine, so you can perform the entire micro-EDM process on one desktop unit.
Features & Benefits
Produce holes as small as 5µm with depths of five times the diameter
Achieve surface roughness of only 0.1µm Rmax
Use of relaxation generator as the pulse electro-discharge generating circuit substantially reduces power levels and provides greater precision
Positioning parameters of less than 1µm for maximum repeat machining accuracy
Especially suited to micro-machine electronic circuit elements on silicon wafers
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Electrode copper
- Electrode copper for the F-Tool holders
In no time at all ready fot application.
- Electrode copper for square clamp
Incl. milled phase 45° for the safe, direction-oriented application.
- Electrode copper for square clamp
Incl. milled phase 45° for the safe, direction-oriented, and with lapped stop-surface for the accurate application.
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Some of the features of these models:
• 4 different models:
NX3 (x-y-z): 400 x 300 x 300 mm
NX4 (x-y-z): 600 x 400 x 400 mm
NX6 (x-y-z): 1000 x 600 x 500 mm
NX7 (x-y-z): 1500 x 750 x 650 mm
• Machines designed to facilitate the automation of work of every kind, with lower outlay cost. They can incorporate a 40-position electrode changer (ø 51 mm – 2 inches).
• A newer, faster, more powerful ONA-S64 CNC, with Windows-based platform, enabling an Ethernet connection allows for reports on machines performance to be sent to mobile phone or PC.
• New function A-SPACE (Axis for erosion in SPACE). With this function, any programmable CNC erosion function (spheres, taper machining, orbital machining, vectors, etc.) can be carried out in any spatial direction.
• New module 3D SETUP that includes an extensive set of automatic measurement cycles (automatic balances in any direction of the space, a utomatic alignment of the axis-machine to the axis-piece, etc.)
• CNC with Expert Erosion System that ensures 100% performance without supervision (with surface finish to VDI =0 - Ra 0.10 µm).
• The mechanical design of the fixed bedframe allows wide travels on the X and Y axes, a high load capacity and high stability.
• Large cost savings. The filter fitted in the NX machines is totally automated and guarantees over 10,000 hours of operation with zero maintenance costs. Filtering quality is excellent (1 µm).
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AQ15L
Linear Motor Drive Large Size Die Sinker EDM
A large size die sinker EDM specialising in the highly efficient production of large size moulds such as those for automobile parts and large flat display panels, making it possible to fully utilise the high speed, high precision machining capability of linear motor drive machines.
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EDM die sinking reproduces, in a metallic workpiece, the shape of a tool called electrode. Injection molds for plastic parts are very frequently machined by die sinking.
The shape given to the electrode is that of the object that is going to be molded. In the machining area, each discharge creates a crater in the workpiece (material removal) and an impact on the tool (wear of the tool/electrode).
There is never any mechanical contact between the electrode and workpiece. The electrode is usually made of copper or graphite.
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Die-Sinker EDM which features high speed, high quality machining perfomance and high operability
"Zero-wear" (wear rate of less than 0.06% is defined as zero-wear)
While machining with graphite electrode, "Zero-Wear" has been made possible, making full advantage of high speed machining performance of graphite electrode.
Large reduction of machining time and human errors can be expected thanks to the reduced number of electrodes.
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* NEW 3D and Multi-Axis-µEDM CNC controller SX-CU offers new possibilities on the Micro-Machining with new dedicated SARIX Technologies of 3D Micro-Milling. Its combination with a continuous automatic wear compensation spindle and a "built in "Micro Wire-EDM electrode grinding device opens up new perspectives on the micro machining of ;
* 3D Micro Milling of complexes forms with radius corner down to 3 microns
* perfect fins walls and microstructures
* high precision of smaller, deeper and more precise perfect round holes
* high surface finishing of Micro Sinking cavities
* NEW SX-MMI, "On-board", easy and user friendly unlimited programming and editing software.
* NEW SX-µEDM-CAM SARIX Modul compatible to ESPRIT CAD-CAM software, integrates the new Micro-EDMing process "Multi-Axis-Multi-Step" for the machining down to 10 microns with Ra up to 0.05.
* High precision machining and accuracy up to ±1 micron.
* High performance Micro Fine Pulse Shape generator SX-MFPS for 3D Micro EDMing machining using tubes and solid electrodes from 5 microns to 3.0 mm.
* High Speed Micro EDM Drilling Technology with automatic breakthrough detection device.
* "High production capability concept" upto 8 axis for complex work pieces with X-Y-Z, back slide W-axis (Z2), C and A/B indexing axi
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K1BL
High-speed hole EDM by Sodick for micro-holes of 0.08 mm diameter
The K1BL is an easy-to-use micro-hole EDM machine for hole diameters up to 0.08 mm.
Its strengths lie in the machining of steels, nonferrous metals, and other difficult materials. With a linear drive for the z axis, it operates with vibration-free precision and high dynamic response in the drilling of holes between 0.08 and 0.25 mm in diameter.
Highly responsive linear motors secure continuous and high precision drilling of very small holes down to the use of 80 micron electrodes. The machinining scope of K1BL, equipped with a Sodick linear motor on the main (Z axis) completes the range. In addition the high response of the linear motor increases the machining speed and reduces the electrode wear significantly.
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The Drill 11 is a production machine designed for the drilling of parts in hard materials such as hardened steel or carbide. Its drilling capability ranges from 0.3 to 3.0 mm diameter through a depth of 200 mm. Particularly simple and easy to use, the 3 axes (X, Y, Z) numerical control makes it possible to program a series of holes for fully automatic machining.
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Best-seller machine for drilling small holes
Drilling hardened hard materials to non-metal materials such as aluminum within seconds
Using Sodick’s original water-soluble dielectric fluid VITOL-KS developed for high-speed drilling, K1C drills holes with pipe electrodes Φ0.25 to 3.0 mmwithin a matter of seconds. The machine is capable of drilling a wide variety of materials from difficult-to-cut materials to aluminum and other non-metal materials (material: SKD11, thickness: 20 mm, electrode diameter: Φ0.8 mm, drilling time: 20 sec.).
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Elements for EDM machines
Applications
For the filtration of dielectric medium in wire erosion and sink erosion machines.
Advantages
Long service life
OEM quality
Recommended by machine producers
References
Agie, Charmilles, Novotec, Intech, Fanuc, Ingersoll-Hansen
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New forms with blocks and blanks
IBIDEN, specialised in electronics and ceramics, produces since 1976 high-class, isostatic manufactured EDM graphite. In the sinking EDM business, the graphite is a more and more deciding factor for quality and performance. F-Tool delivers you prepared blocks and blanks ready to run.
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Graphite is used as an electrode material in electrical discharge machining. Compared to copper, graphite offers a number of advantages that benefit the entire process chain of molding and forging tool manufacture. These advantages significantly reduce the cost of tools manufactured by electrical discharge machining, while maintaining or even enhancing quality standards.
SGL Group offers a wide range of electrical discharge electrodes with finishes ranging from coarsely roughened to ultrafine.
We supply standard semifinished products in rectangular and cylindrical formats, as well as blanks manufactured to customer specification and also ready-to-use electrodes matched to your clamping system.
We offer a 24-hour delivery service for all semifinished products and a number of standard products.
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AP1L
Premium High End EDM Machine
Responding to the need for a higher level of machining accuracy, Sodick’s AP1L Premium offers solutions to ultra precision machining requirements based on achieved superiority in mini and microscopic machining. Production is improved through advanced functions for automation and labour saving operation. Revolutionary technology is needed for electrode dressing to support ultra precision high speed machining of hard and difficult materials in order to achieve manufacturing capability of mini and micro moulds.
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ONA DB series
- New high-speed pulse technology, which allows to get the following results:
* Shorter machining times in jobs that involve very difficult flushing.
* More homogeneous finish on large surface areas (VDI 20 on 225 cm²).
* Very deep grooves can be machined, with the highest quality and precision guaranteed
(VDI 20 up to 100 mm).
- The Expert System featured in the generator of the ONA DB 300 models ensures totally automated production with one hundred percent performance and an excellent finish.
- Surface finish of up to VDI = 0. This machines include a high-performance generator in removal operations, while at the same time preserving the electrodes and allowing excellent performance in fine finish mode (up to VDI = 0).
- Subsurface injection function. A great aid to speed when the injection points required by a mould are being realized.
- Important savings. The filter featured optionally in the ONA serie DB machines guarantees over 10,000 hours in operation with zero maintenance costs. Filtering quality is excellent (1 micron).
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It can be universally applied and permanently reduces your operating costs: the EA12-V series. On account of its reliability, capability and availability, it is one of the most sought after erosion systems in the world. Its high-quality design and multifaceted technological innovations are equally as persuasive. The newly developed high performance FP80V generator provides the highest productivity and best results on the work piece. The generator's strengths are fully utilised with regard to the processing of tungsten carbide - even with standard copper electrodes. The combination of the lowerable working tank together with the optional left/right hand placement of the generator/control cabinet, makes automation as flexible as possible. The EA12-V which is constructed with a solid, cast steel frame also has a digital direct drive as well as an absolute measuring system. In addition, the EA12-V is equipped with a direct linear way measuring system that guarantees consistent precision.
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The expanding world of EDM. As a result of technological innovations in metal cutting processes, most die and mold machining operations are now done on machining centers. At the same time, though, dramatic progress has been achieved in the machining speed, accuracy and surface finish of electrical discharge machining. Die and mold makers are now taking another look at the many benefits of EDM. Makino's EDNC Series incorporates a wide variety of advanced features to deliver optimum machining performance that clearly demonstrates the expanding possibilities of EDM machines.
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ONA NX series with modular design:
• Over 40 different models of large die-sinking EDM machines:
• The large scale ONA NX series, uses a modular design to allow many configurations. Each customer can configure, with a great flexibility, the machine that meets his exact requirements.
• This new series utilizes pre-built axes modules to drastically reduce machine assembly time.
• Each customer can get a custom system for the same price and lead time as a standard machine.
• Manifold configurations of X-Y-Z travels:
- X travel: 1500, 2000 or 3000 mm
- Y travel: 750, 1000 or 1500 mm
- Z travel: 650, 800 or 1000 mm
• One or two heads commanded by two independent CNC generators. This allows the possibility of eroding two cavities simultaneously and independently in a big workpiece.
• Highly rigid mechanical structure constructed Mehanite cast
• Fixed bedframe machine that allows work pieces up to 15.000 kg (33,000 lb).
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Electrical Discharge Machining: die sinking EDM
