Reducing process time for large mold tooling

Source：Ringier Metalworking Release Date：2016-02-11 198

Metalworking

As the design complexity of extra-large workpieces continues to grow, manufacturers in Asia must identify new means for processing a wider variety of small intricate features with maximum throughput.  

Brian Pfluger, EDM product line manager explains the dual-head configuration of the EDNC21 sinker electrical discharge machine (EDM) from Makino enables shops to process multiple fine details in a workpiece at the same time, significantly reducing total processing time.

Due to its rigid and precise construction, the EDNC21 is capable of achieving the same level of accuracy and surface finish as sinker EDM machines one-tenth its size.

The EDNC21 offers a sizable work envelope of 122.0 inches by 70.9 inches by 39.4 inches (3,100 mm by 1,800 mm by 1,000 mm) to accommodate extra-large workpieces, such as automotive bumper and fascia molds. The X-, Y- and Z-axes of the machine provide cumulative travels of 78.7 inches, 59.1 inches and 23.6 inches (2,000 mm, 1,500 mm and 600 mm), respectively.

Each of the EDNC21’s gantry-style heads is capable of traveling up to 78.7 inches (2,000 mm) and is independently controlled and programmed using a dedicated Hyper-i control system for each head. The EDNC21 provides a total workpiece payload of 22,047 lbs. (10,000 kg) and accommodates electrode weights up to 662 lbs. (300 kg) per head.

The design of the EDNC21 includes a programmable rise-and-fall front door for easy operator access during setup and operation. Door height, which controls dielectric fluid level, can be set to match the height of the workpiece while providing optimum viewing of the machining operation.

Each EDNC-Series machine is equipped with the new Hyper-i control system, which is the same system used on Makino’s wire EDM products, signifying a standardization of Makino’s EDM machine controls. Hyper-i improves productivity by streamlining and simplifying the machine interface so that operators of all skill levels can achieve the most efficient results.

Its 24-inch high-definition monitor provides touch-screen technology similar to that of smartphones and tablets, enabling the use of pinch, swipe and spread movements to select machining conditions for workpiece and electrode material type, and the desired feature shape and surface finish. The user friendliness of the Hyper-i control is further enhanced with the integration of on-board digital manuals, intelligent E-Tech Doctor help functions, and an e-Learning training system.

Additional Performance Enhancing Technologies

SuperSpark IV: SuperSpark IV is an advanced adaptive control technology that optimizes the machining discharge power and electrode jump motions during roughing and finishing operations. This technology is especially effective on rib or drafted electrodes; and, when combined with HyperCut settings, it can reduce total machining time by up to 50 percent.

High-Quality Surface Finish Option: All EDNC-Series sinker EDMs can be equipped with Makino’s proprietary High-Quality Surface Finish™ (HQSF) technology that yields achievable surface finish capabilities 50 percent better than conventional surface finishes, regardless of discharge surface area. The HQSF technology can extend tool life through improved surface integrity, and can also reduce cycle time even when fine surface finishes are not required.

High-Speed Z-Axis Option: The HS-Rib Z-axis configuration reduces rough machining speeds of small electrodes, such as plastic injection tooling ribs or pin gate details, and provides enhanced jump speeds of up to 20 m/min that can reduce machining times by up to 60 percent.

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