EDM capability gets a new lease of life

The new machines, a AC Progress VP2 (wire) and a FORM 200 (die-sink, were installed at VTL Group's Technical Solutions Centre in Huddersfield during March and April 2012 and are currently being used to help manufacture high precision, complex components such as synchroniser rings and turbo chargers for many of the world's leading automotive OEMs and Tier 1 companies.

The Technical Solutions Centre was opened in 2011 and houses the Group's R&D department and Technical Services. It provides VTL's customers with a comprehensive resource focused on product development and manufacturing innovation. The range of services provided includes technical consultancy support, process design and implementation, software simulation and advanced manufacturing and testing.

“The Centre provides customers with the latest in precision engineering technologies to help their current and future product development needs and requirements,” explained technical development manager, Mark Richardson. It brings together the expertise and experience within the VTL Group, as well as from a number of academic and industrial partners, to offer a total systems solutions-based consultancy service.

EDM is a core technology for the Centre with the two new GF AgieCharmilles machines replacing older models. “We rely on our EDM machines to manufacture complex, high precision parts and intricate part features such as thin walls and geometrically tight radii,” Mr Richardson revealed. To be honest, our older machines simply weren't up to scratch in terms of part accuracy, repeatability and process reliability.”

The AC Progress VP2 wire EDM machine provides fast cutting speeds of 500mm²/minute and can produce surface finishes of Ra 0.2µm. It is equipped with the latest, high performance digital generator and powerful Agievision 5 control system.

The machine exhibits a number of productivity enhancing features such as Duotec wire technology, AWT (Automatic Wire Thread) capability designed to help manufacturers reduce set-up times, cycle times, and reduce operating costs.

The performance attributes of the new die-sink machine – the FORM 200 – are similarly impressive and include Zero Wear IQ technology which is said to significantly reduce electrode wear and, as a consequence, consumable costs.

“We are exploiting the potential of our new EDM technology and are putting our new machines through their paces. We have experienced significant productivity gains since their installation and the decision to invest in the new technology has been vindicated,” Mr Richardson concluded.
GF Agie Charmilles
www.gfac.com/uk