Unattended Die Sinking EDM Machines Ratchet up Efficiency

The FORM P 350 die sinking EDM machine from GF Machining Solutions LLC (Lincolnshire, IL) features precision-enhancing design qualities along with several integrated technologies to enable shops to easily enhance productivity and profitability. A compact C-axis construction, fixed table and cast iron frame offer high stability and force reduction to help maintain a precise spark gap between the part and the electrode. Regardless of part weight or dielectric volume, the FORM P 350 delivers consistent accuracy and a best surface finish of Ra 0.1 μm. Integrated glass scales preserve long-term, repeatability and eliminate the need for recalibration as well as any errors found in traditional screw systems due to backlash and wear. At the heart of the machine is a high-end Intelligent Power Generator (IPG), one of the world’s most powerful generators for die sinking EDMs.

With integrated, quality enhancing and cost-saving intelligence, a TECFORM module ensures that the EDM process is continuously optimized with each pulse to significantly reduce electrode wear or obtain the finest finishes. The embedded TECFORM module allows the FORM P 350 to quickly and safely achieve the best performance and desired results. Segment-dedicated technology eliminates the need for the operator to adjust the generator’s parameters. Spark process control takes a fraction of a second and produces an extremely homogeneous surface finish. In combination, these features yield greater reliability, improved machining efficiency and significantly less unproductive time.

Equipped with breakthrough iQ (innovation + quality) groundbreaking technologies to control the erosion process of graphite and/or copper electrodes, the FORM P 350 is highly effective at reducing costs in die sinking operations. iQ technology brings together fast and efficient electronics capable of real time spark characteristic analysis and adjusts the current setting as needed for absolute pulse efficiency. This ensures wear-free spark erosion, high precision, extremely efficient performance, unparalleled respect for detail, and greater control over the cost of the electrode. The machine console is equipped with the user-friendly AC FORM HMI (human machine interface) that is based on a standard Windows® platform and offers interactive graphical assistance so that all operations, such as measurement and machining cycles, are illustrated by graphics/icons for fast operator understanding and ease of use. It provides simple descriptions of machining targets, automatic selection of optimal technology and dynamic parameters adaption.

The FORM P 350 comes standard with a four-position linear tool changer for System 3R macro tooling. A Rotary Tool Changer (RTC) can be added to replace the four-position linear tool changer on the left side of the machine to increase the number of electrodes up 160 in a very small space. The FORM P 350 can also be paired with the System 3R WorkPartner 1+ robot for unattended night and weekend operation. With X/Y/Z axes travels of 17.8 in x 9.8 in x 11.8 in (350 mm x 250 mm x 300 mm), shops can efficiently machine workpieces up to 27.6 in x 18.1 in x 10.8 in (700 mm x 460 mm x 275 mm).

GF Machining Solutions also offers their compact FORM E 350 die sinking EDM for small shops. With the smallest footprint on the market, this machine boasts a sturdy C-axis construction, cross table and cast iron frame that offer high stability and force reduction to help maintain a precise spark gap between the part and the electrode. Regardless of part weight or dielectric volume, the machine delivers consistent accuracy. Integrated glass scales preserve long-term, repeatability and eliminate the need for recalibration as well as any errors found in traditional screw systems due to backlash and wear. The latest-generation Intelligent Speed Power Generator (ISPG) on the FORM E 350 excels at superior surface finishes and precision applications in any conductive material. It overcomes common process challenges for copper electrodes, including electrode wear induced by electrical discharge. ISPG improves machining speeds by 40 percent and reduces corner wear by 50 percent.

Designed for high efficiency on the shop floor, the machine features a programmable dielectric management system with a 270 lit capacity integrated inside the machine cabinet. This system fills and empties the work tank without human intervention to keep the machine in production and is easy to access for routine maintenance. The machine console comes equipped with the user-friendly AC FORM HMI that provides simple descriptions of machining targets, automatic selection of optimal technology and dynamic parameters adaption. With an X/Y/Z travel of 17.8 in x 9.8 in x 9.8 in (350 mm x 250 mm x 250 mm), the FORM E 350 handles workpieces up to 31.5 in x 19.7 in x 10.4 in (800 mm x 500 mm x 265 mm.) It also has a four-position linear tool changer. The FORM E 350 is automation ready and can easily be paired with the System 3R WorkPartner 1+ robot to implement unattended night and weekend operation.

GF Machining Solutions LLC, 560 Bond Street, Lincolnshire, IL 60069-4224, 847-913-5300, Fax: 847-913-5340, www.gfms.com/us.