Intelligent wire erosion 

The Cut P 350/550/800/1,250 machines feature efficient digital power generators, robust designs and intuitive human-machine-interfaces (HMIs), as well as several automation options for lights-out and unattended operations.

With Intelligent Power Generator (IPG) technology, the EDMs deliver surface finishes as good as Ra 0.10µm and boost cutting speeds by up to 20% over previous models. Several ‘Expert’ systems further optimise the IPG’s (generator) cutting performance, especially for challenging applications.

The Power-Expert software module monitors and changes power levels required when the machine is cutting parts with variable heights.

The system protects the parts from unstable conditions while the machine maintains high cutting speeds. Simultaneously, this system controls the spark parameters during finish operations to provide high-quality surface finishes on variable-height parts. This maximises part finishes and significantly reduces the need for secondary benchwork.

Regardless of workpiece height, the Wire-Expert system dynamically controls wire wear to achieve continuous and consistent geometrical accuracy from all directions.

For part profile accuracy, Profil-Expert automatically adapts the machining parameters and the cut path for rough and skim passes to provide excellent control of fine details and to ensure positioning and contour accuracies of ±2µm, while Taper-Expert technology cuts angles from 0 to 30° (45° as an option) to maximum Z heights.

Taper-Expert corrects shifts of the Z-reference position in real time, even when the taper angle is changing. The taper angle is also held to within 10 seconds on average, providing taper accuracy and geometry reference accuracy throughout the taper cut.

The fixed tables on the machines provide rigidity and stability that ensure accuracy when machining heavy workpieces.

Integrated temperature regulation (thermal compensation) systems consistently maintain temperatures within ±0.2°C, which guarantees repeatability over long periods of time. However, in shops where the ambient temperature fluctuates throughout the day, a thermostability option provides an extra layer of temperature control protection from thermal effects on machine axes.

The machines also feature GF Machining Solutions’ collision protection technology (ICP) in the X-, Y-, U-, V- and Z-axes that prevents potential machine damage and eliminates costly down time and maintenance, even at maximum axis travel speeds of 3m/minute.

The Windows-based AC CUT HMI 2 user interface on the machines simplifies file management and maximises operator efficiency with its 19-inch, touchscreen and i7 CPU technology.

This system also supports intuitive programming directly on the control as well as imported CAD/CAM files with built-in AC CAM Easy CAD/CAM software. The EDM series is also ready for the Internet of Things/Industry 4.0 with eConnectivity features that connect the machine to larger shop management systems for effective monitoring and increased machine utilisation.

New automation solutions, including Automatic Slug Management (ASM), Automatic Slug Welding (ASW) and Renishaw probing systems, reduce processing time by up to 20% in lights-out operations.

Additionally, the Cut P 350 and 550 machines can integrate with robots such as the System 3R WorkPartner 1+ that automatically loads and unloads parts for a single machine or within a two-machine automation cell that doubles machine production capacities.

With more than 600 dedicated, pre-programmed cutting processes, the machines optimise production for electronics, automotive, medical and mould tool and die manufacturers. The machines can be used to machine parts ranging from less than 1mm up to 800mm in height, weighing up to 6,000kg made of a host of materials from steel, carbide and copper to aluminium, titanium and graphite.

Wires are available in 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm and 0.33mm diameters.

GF Machining Solutions www.gfms.com/uk