Controlling sparks improves EDM wire life

Spark Track is GF Machining Solutions latest EDM software monitoring system that adjusts the rate and intensity of sparks along the length of the wire and, in doing so, prevents heavy wear from occurring at any point on the wire – extending its life and preventing breaks.

At the heart of the innovation is GF’s generator technology – specifically its high-performance ISPS (Intelligent Spark Protection System) module – which accurately identifies the intensity and location of sparks along the wire and, when necessary and required, adjusts current and voltage rates to prevent concentration of wear on the wire.

Spark Track provides comprehensive and real-time spark distribution information to manufacturers, enabling them to push their EDM machines to the limit.

Martin Spencer, managing director at GF Machining Solutions UK says: “The ISPS module eliminates wire breakage regardless of machining conditions and, as such, makes manufacturers’ wire EDM processes more reliable and secure.

Spark Track solves problems such as wire oscillation which can occur when machining different heights and tapered surfaces, and can lead to wire breaks and damaged workpieces.

“Superior wire cutting performance is achieved when discharge distribution, along the wire, is as uniform as possible. Spark Track enables this to occur,” Mr Spencer continues.

ISPS and Spark Track, working in combination, not only prevent wire breaks they also, as a consequence, eliminate time intensive resets and reduce the amount of time an operator has to devote to a given job. They also help extend wire life.

Other recent developments introduced by GF Machining solutions to better regulate the spark output of its machines include: the standardisation of high-performance generators across all of its EDM machines; and the redesign of its machines and the positioning of its generators to place them as close to the wire as possible.

This makes the machines more responsive and able to react quickly to inputs from the control by reducing the distance computer signals and sparks need to travel.

GF Machining Solutions www.gfms.com/uk