Spark Track Technology Prevents Wire Breakage for Easy, Stable EDM Processes

Two fully automatic functions on the restyled AgieCharmilles CUT 2000 X wire EDM from GF Machining Solutions (Lincolnshire, IL) ensure unmatched accuracy and productivity in demanding applications by increasing machining efficiency and minimizing operator intervention.

Winner of a 2019 PRODEX Award for pioneering products, Spark Track technology prevents wire breakage when cutting irregularly shaped workpiece features.

Angled surfaces, for example, can disrupt the machining process by creating non-homogenous flushing conditions at a machine’s upper nozzle. GF Machining Solutions’ Intelligent Spark Protection System (ISPS) prevents that by harnessing sensor signal, speed, and effectiveness to recognize and analyze shape changes and automatically adjust machining parameters to prevent breaking during roughing.

As a result, cavities, varying heights, taper surfaces, and sharp corners are easily roughed without the operator having to set up machining conditions in advance. By providing 100% automation, the highly secure cutting process lowers cost per part.

With Integrated Vision Unit (IVU) Advance, users save setup time, check reference points without a measuring machine, and correct machining errors to achieve the best quality and increase productivity.

A charge-coupled-device (CCD) camera mounted on the machine analyzes light intensity variation to detect edges, saving costs and facilitating closed-loop manufacturing. At the same time, multiple measurement systems are available for part control and setup along with automatic shutter and part-cleaning solutions.

Users achieve greater autonomy over results with the integration of automation-compatible, total measurement control.

Open guides on the automatic wire changer (AWC) allow manufacturers to use a combination of different diameters between roughing and  finishing, thereby reducing machining time for small and complex geometries – resulting in up to 32% greater productivity. Additionally, two 55-lb (25-kg) wire spools eliminate the need to modify the wire circuit when switching wires, which increases flexibility.

Vision 5 software allows manufacturers to optimize production with flexible job management. The interface simplifies last-minute machining sequence modifications and allows for special actions to be introduced directly inside the job to ramp up quality and productivity.

GF Machining Solutions, 560 Bond St., Lincolnshire, IL 60069, 847-913-5300, fax: 847-913-5340, www.gfms.com/us.