Die-Sinking EDM Optimizes Micromachining Processes

GF Machining Solutions showcases the AgieCharmilles Form X 400 die-sinking EDM solution paired with the System 3R’s WorkShopManager (WSM) and WorkPartner 1+ (WPT1+) compact part and electrode changing robot.

The Form X 400 features the intelligent speed power generator, so users can utilize the machine series’ discharge circuit to provide spark erosion power modulation for high flexibility and maximum material removal. The system optimizes micromachining processes so that fewer electrodes are needed to machine sharp internal corners. The Form X series also includes the latest generation of the AC Form human-machine interface. The series’ software ensures greater reliability, improved machining efficiency and less unproductive time for the highest level of precision and machine performance. The series’ Tecform Expert module enables the machine to quickly and safely produce desired results. For further process optimization, industry-specific technologies free the machine operator from the task of adjusting the generator’s parameters. For high-accuracy part processing, the Form X 400 includes a thermal control system that uses temperature-stable dielectric fluid to cool the machine’s X, Y and Z-axis glass scales and the Z-axis ball screw. Additionally, the machine body is thermally isolated from the high-speed Z axis, and all moving parts are fully disassociated from the loading and machining area, all of which ensures that temperature variations and particularly heavy or light workpieces cannot affect machining and measuring accuracy.

With its central database, the System 3R WSM keeps production running on the Form X 400 with standardized procedures and manages the automation process. Job lists can be interrupted with WSM so urgent parts can be machined; upon completion, the cell automatically returns to the list of jobs to be executed. Additionally, WSM helps eliminate the need to have all parts and electrodes 100% ready before executing a job. Machining can start while the parts and electrodes are being measured and loaded into the robot magazine, and WSM seamlessly updates the information about the running job as parts are loaded.

To accommodate all the Form X machines, the System 3R WPT1+ is available in nine modular models that meet the needs of a broad range of milling, grinding, EDM and laser micromachining equipment. The system can serve one or two machines in a production cell with its flexible one, two or three-magazine capacity, and its pneumatic control for gripping devices and table chucks is fully integrated. The WPT1+ offers maximum magazine capacity in minimal floor space and is efficient for both one-off and serial production due to magazine doors for loading and unloading and rapid change cycles.