Makino introduces its EDNC21 sinker electrical discharge machine (EDM) with dual heads that provide an industry-changing advantage by improving productivity and lowering the tool build time for large molds. The EDNC21 also includes Makino’s latest EDM innovations and developments including the Hyper-i control, HyperCut technology, and new HS-Rib high speed Z-Axis.

“As the design complexity of extra-large workpieces, such as automotive bumper and fascia molds, continues to grow, manufacturers must identify new means for processing a wider variety and volume of small intricate features with maximum throughput,” explained Brian Pfluger, Makino’s EDM product line manager. “The dual-head configuration of the EDNC21 enables shops to process multiple fine details in a workpiece at the same time, significantly reducing total processing time. Due to its rigid and precise construction, the EDNC21 is capable of achieving the same level of accuracy and surface finish as sinker EDM machines one-tenth its size.”

The EDNC21 offers a sizable work envelope of 122.0 inches by 70.9 inches by 39.4 inches (3,100 mm by 1,800 mm by 1,000 mm) to accommodate extra-large workpieces, such as automotive bumper and fascia molds. The X-, Y- and Z-axes of the machine provide cumulative travels of 78.7 inches, 59.1 inches and 23.6 inches (2,000 mm, 1,500 mm and 600 mm), respectively. Each of the EDNC21’s gantry-style heads is capable of traveling up to 78.7 inches (2,000 mm) and is independently controlled and programmed using a dedicated Hyper-i control system for each head. The EDNC21 provides a total workpiece payload of 22,047 lbs. (10,000 kg) and accommodates electrode weights up to 662 lbs. (300 kg) per head.

The design of the EDNC21 includes a programmable rise-and-fall front door for easy operator access during setup and operation. Door height, which controls dielectric fluid level, can be set to match the height of the workpiece while providing optimum viewing of the machining operation.

Every Makino EDNC-Series machine also includes these features:

– High-mass castings to ensure mechanical and thermal stability
– Stationary table for accurate positioning regardless of workpiece size or weight
– Space-saving integrated reservoir in the base casting to reduce machine size and to achieve greater thermal stability
– Dual-anchored, direct-drive ballscrews that maintain precision long term

Revolutionary Hyper Technologies
Similar to other EDNC-Series sinker EDM machines, the EDNC21 is designed with Makino’s proprietary Hyper technologies, which ensure an ideal mix of speed, finish, and reduced electrode wear.

HyperCut technology is a new generator function that increases power levels without requiring additional reduction on the electrode, and it improves roughing speeds by up to 30 percent without affecting workpiece accuracy or surface quality. The technology minimizes electrode wear while providing the fastest possible machining speed.

Each EDNC-Series machine is equipped with the new Hyper-i control system, which is the same system used on Makino’s wire EDM products, signifying a standardization of Makino’s EDM machine controls. Hyper-i improves productivity by streamlining and simplifying the machine interface so that operators of all skill levels can achieve the most efficient results. Its 24-inch high-definition monitor provides touch-screen technology similar to that of smartphones and tablets, enabling the use of pinch, swipe and spread movements to select machining conditions for workpiece and electrode material type, and the desired feature shape and surface finish. The user friendliness of the Hyper-i control is further enhanced with the integration of on-board digital manuals, intelligent E-Tech Doctor help functions, and an e-Learning training system.

Additional Performance Enhancing Technologies
SuperSpark IV: SuperSpark IV is an advanced adaptive control technology that optimizes the machining discharge power and electrode jump motions during roughing and finishing operations. This technology is especially effective on rib or drafted electrodes; and, when combined with HyperCut settings, it can reduce total machining time by up to 50 percent.

High-Quality Surface Finish Option: All EDNC-Series sinker EDMs can be equipped with Makino’s proprietary High-Quality Surface Finish (HQSF) technology that yields achievable surface finish capabilities 50 percent better than conventional surface finishes, regardless of discharge surface area. The HQSF technology can extend tool life through improved surface integrity, and can also reduce cycle time even when fine surface finishes are not required.

High-Speed Z-Axis Option: The HS-Rib Z-axis configuration reduces rough machining speeds of small electrodes, such as plastic injection tooling ribs or pin gate details, and provides enhanced jump speeds of up to 20 m/min that can reduce machining times by up to 60 percent.

Makino introduces its EDNC21 sinker electrical discharge machine (EDM) with dual heads that provide an industry-changing advantage by improving productivity and lowering the tool build time for large molds. The EDNC21 also includes Makino’s latest EDM innovations and developments including the Hyper-i control, HyperCut technology, and new HS-Rib high speed Z-Axis.

“As the design complexity of extra-large workpieces, such as automotive bumper and fascia molds, continues to grow, manufacturers must identify new means for processing a wider variety and volume of small intricate features with maximum throughput,” explained Brian Pfluger, Makino’s EDM product line manager. “The dual-head configuration of the EDNC21 enables shops to process multiple fine details in a workpiece at the same time, significantly reducing total processing time. Due to its rigid and precise construction, the EDNC21 is capable of achieving the same level of accuracy and surface finish as sinker EDM machines one-tenth its size.”

The EDNC21 offers a sizable work envelope of 122.0 inches by 70.9 inches by 39.4 inches (3,100 mm by 1,800 mm by 1,000 mm) to accommodate extra-large workpieces, such as automotive bumper and fascia molds. The X-, Y- and Z-axes of the machine provide cumulative travels of 78.7 inches, 59.1 inches and 23.6 inches (2,000 mm, 1,500 mm and 600 mm), respectively. Each of the EDNC21’s gantry-style heads is capable of traveling up to 78.7 inches (2,000 mm) and is independently controlled and programmed using a dedicated Hyper-i control system for each head. The EDNC21 provides a total workpiece payload of 22,047 lbs. (10,000 kg) and accommodates electrode weights up to 662 lbs. (300 kg) per head.

The design of the EDNC21 includes a programmable rise-and-fall front door for easy operator access during setup and operation. Door height, which controls dielectric fluid level, can be set to match the height of the workpiece while providing optimum viewing of the machining operation.

Every Makino EDNC-Series machine also includes these features:

– High-mass castings to ensure mechanical and thermal stability
– Stationary table for accurate positioning regardless of workpiece size or weight
– Space-saving integrated reservoir in the base casting to reduce machine size and to achieve greater thermal stability
– Dual-anchored, direct-drive ballscrews that maintain precision long term

Revolutionary Hyper Technologies
Similar to other EDNC-Series sinker EDM machines, the EDNC21 is designed with Makino’s proprietary Hyper technologies, which ensure an ideal mix of speed, finish, and reduced electrode wear.

HyperCut technology is a new generator function that increases power levels without requiring additional reduction on the electrode, and it improves roughing speeds by up to 30 percent without affecting workpiece accuracy or surface quality. The technology minimizes electrode wear while providing the fastest possible machining speed.

Each EDNC-Series machine is equipped with the new Hyper-i control system, which is the same system used on Makino’s wire EDM products, signifying a standardization of Makino’s EDM machine controls. Hyper-i improves productivity by streamlining and simplifying the machine interface so that operators of all skill levels can achieve the most efficient results. Its 24-inch high-definition monitor provides touch-screen technology similar to that of smartphones and tablets, enabling the use of pinch, swipe and spread movements to select machining conditions for workpiece and electrode material type, and the desired feature shape and surface finish. The user friendliness of the Hyper-i control is further enhanced with the integration of on-board digital manuals, intelligent E-Tech Doctor help functions, and an e-Learning training system.

Additional Performance Enhancing Technologies
SuperSpark IV: SuperSpark IV is an advanced adaptive control technology that optimizes the machining discharge power and electrode jump motions during roughing and finishing operations. This technology is especially effective on rib or drafted electrodes; and, when combined with HyperCut settings, it can reduce total machining time by up to 50 percent.

High-Quality Surface Finish Option: All EDNC-Series sinker EDMs can be equipped with Makino’s proprietary High-Quality Surface Finish (HQSF) technology that yields achievable surface finish capabilities 50 percent better than conventional surface finishes, regardless of discharge surface area. The HQSF technology can extend tool life through improved surface integrity, and can also reduce cycle time even when fine surface finishes are not required.

High-Speed Z-Axis Option: The HS-Rib Z-axis configuration reduces rough machining speeds of small electrodes, such as plastic injection tooling ribs or pin gate details, and provides enhanced jump speeds of up to 20 m/min that can reduce machining times by up to 60 percent.

Makino announces the latest expansion to its lineup of EDNC-Series sinker EDM machines, the EDNC10, EDNC15 and EDNC20. Designed to provide a powerful blend of power, speed and precision in large work envelopes, these new EDNC sinker EDMs accommodate massive, heavy workpieces while still producing delicate, fine features with high accuracy and exceptional surface finish.

The rigid and precise construction of the EDNC-Series enables the EDNC10, EDNC15 and EDNC20 to achieve the accuracy and surface finish levels found on smaller sinker EDM machines, said Brian Pfluger, Makino’s EDM product line manager.

“Many large-commodity sinker EDMs will see a significant performance drop-off in accuracy, surface finish and machine speed when compared to standard-size sinker EDM machines. The Makino EDNC-Series machines overcome these challenges with key technologies that achieve small-sinker EDM performance on a large-platform machine,” Pfluger said.

Die and mold shops, aerospace and power-generation equipment manufacturers are sure to appreciate the larger work sizes of these machines. Specifications are noted below:

The EDNC10, EDNC15 and EDNC20 feature 60-amp (80 Peak amps) power supplies as standard, with 120 or 240-amp options available. The EDNC10 and EDNC15 machin
es are designed with a full three-sided programmable drop tanks, providing unparalleled ergonomic access for setup and operation. The EDNC20 features a programmable rise and fall front door, which controls dielectric fluid level, and can be set to match the height of the workpiece while providing optimum viewing of the machining operation.

The design of the large EDNC machines also features:

·         High-mass castings to ensure mechanical and thermal stability
·         Stationary table for accurate positioning regardless of workpiece size or weight
·         Space-saving integrated reservoir in the base casting to reduce machine size
·         Dual-anchored direct-drive ballscrews that maintain precision long term

Revolutionary Hyper Technologies
Makino’s proprietary Hyper technologies included on the EDNC10, EDNC15 and EDNC20 ensure the ideal mix of speed, surface finish and reduced electrode wear.

HyperCut technology is a new generator function that increases power levels without requiring additional reduction on the electrode, and it improves roughing speeds by up to 30 percent without affecting workpiece accuracy or surface quality.  The technology minimizes electrode wear while providing the fastest possible machining speed.

Each EDNC-Series machine is equipped with the new Hyper-i control system, which is the same system used on Makino’s wire EDM products, signifying a standardization of Makino’s EDM machine controls. Hyper-i improves productivity by streamlining and simplifying the machine interface so that operators of all skill levels can achieve the most efficient results. Its 24-inch high-definition monitor provides touch-screen technology similar to that of smartphones and tablets, enabling the use of pinch, swipe and spread movements to select machining conditions for workpiece and electrode material type, and the desired feature shape and surface finish. The user friendliness of the Hyper-i Control is further enhanced with the integration of on-board digital manuals, intelligent E-Tech Doctor help functions, and an e-Learning training system.

Additional Performance Enhancing Technologies
SuperSpark IV: SuperSpark IV is an advanced adaptive control technology that optimizes the machining discharge power and electrode jump motions during roughing and finishing operations. This technology is especially effective on rib or drafted electrodes, and when combined with HyperCut settings, can reduce total machining time by up to 50 percent.

High-Quality Surface Finish Option: All EDNC-Series sinker EDMs can be equipped with Makino’s proprietary High-Quality Surface Finish (HQSF) technology that yields achievable surface finish capabilities 50 percent better than conventional surface finishes, regardless of discharge surface area. The HQSF technology can extend tool life through improved surface integrity, and can also reduce cycle time even when fine surface finishes are not required.

High-Speed Z-Axis Option: The HS-Rib Z-Axis configuration reduces rough machining speeds of small electrodes, such as plastic injection tooling ribs or pin gate details, and provides enhanced jump speeds of up to 20m/min that can reduce machining times by up to 60 percent.

Makino announces the latest expansion to its lineup of EDNC-Series sinker EDM machines, the EDNC10, EDNC15 and EDNC20. Designed to provide a powerful blend of power, speed and precision in large work envelopes, these new EDNC sinker EDMs accommodate massive, heavy workpieces while still producing delicate, fine features with high accuracy and exceptional surface finish.

The rigid and precise construction of the EDNC-Series enables the EDNC10, EDNC15 and EDNC20 to achieve the accuracy and surface finish levels found on smaller sinker EDM machines, said Brian Pfluger, Makino’s EDM product line manager.
“Many large-commodity sinker EDMs will see a significant performance drop-off in accuracy, surface finish and machine speed when compared to standard-size sinker EDM machines. The Makino EDNC-Series machines overcome these challenges with key technologies that achieve small-sinker EDM performance on a large-platform machine,” Pfluger said.

Die and mold shops, aerospace and power-generation equipment manufacturers are sure to appreciate the larger work sizes of these machines. Specifications are noted below:

The EDNC10, EDNC15 and EDNC20 feature 60-amp (80 Peak amps) power supplies as standard, with 120 or 240-amp options available. The EDNC10 and EDNC15 machines are designed with a full three-sided programmable drop tanks, providing unparalleled ergonomic access for setup and operation. The EDNC20 features a programmable rise and fall front door, which controls dielectric fluid level, and can be set to match the height of the workpiece while providing optimum viewing of the machining operation.

The design of the large EDNC machines also features:

• High-mass castings to ensure mechanical and thermal stability
• Stationary table for accurate positioning regardless of workpiece size or weight
• Space-saving integrated reservoir in the base casting to reduce machine size
• Dual-anchored direct-drive ballscrews that maintain precision long term

Revolutionary Hyper Technologies

Makino’s proprietary Hyper technologies included on the EDNC10, EDNC15 and EDNC20 ensure the ideal mix of speed, surface finish and reduced electrode wear.

HyperCut technology is a new generator function that increases power levels without requiring additional reduction on the electrode, and it improves roughing speeds by up to 30 percent without affecting workpiece accuracy or surface quality.  The technology minimizes electrode wear while providing the fastest possible machining speed.

Each EDNC-Series machine is equipped with the new Hyper-i control system, which is the same system used on Makino’s wire EDM products, signifying a standardization of Makino’s EDM machine controls. Hyper-i improves productivity by streamlining and simplifying the machine interface so that operators of all skill levels can achieve the most efficient results. Its 24-inch high-definition monitor provides touch-screen technology similar to that of smartphones and tablets, enabling the use of pinch, swipe and spread movements to select machining conditions for workpiece and electrode material type, and the desired feature shape and surface finish. The user friendliness of the Hyper-i Control is further enhanced with the integration of on-board digital manuals, intelligent E-Tech Doctor help functions, and an e-Learning training system.

Additional Performance Enhancing Technologies
SuperSpark IV: SuperSpark IV is an advanced adaptive control technology that optimizes the machining discharge power and electrode jump motions during roughing and finishing operations. This technology is especially effective on rib or drafted electrodes, and when combined with HyperCut settings, can reduce total machining time by up to 50 percent.

High-Quality Surface Finish Option: All EDNC-Series sinker EDMs can be equipped with Makino’s proprietary High-Quality Surface Finish (HQSF) technology that yields achievable surface finish capabilities 50 percent better than conventional surface finishes, regardless of discharge surface area. The HQSF technology can extend tool life through improved surface integrity, and can also reduce cycle time even when fine surface finishes are not required.

High-Speed Z-Axis Option: The HS-Rib Z-Axis configuration reduces rough machining speeds of small electrodes, such as plastic injection tooling ribs or pin gate details, and provides enhanced jump speeds of up to 20m/min that can reduce machining times by up to 60 percent.

Makino introduces its latest innovation in wire EDM technology, the U1310 wire EDM machine. Designed to substantially improve ease of operation, machining speed and accuracy in large workpiece applications, the U1310 delivers unmatched versatility and flexibility for a wide range of industries.

“Too often, manufacturers assume that the larger the workpiece, the less precise the performance,” said Brian Pfluger, EDM product line manager at Makino. “The U1310 debunks this myth by providing superior levels of precision even when compared to smaller travel EDM machines. With features like Makino’s high-energy applied technology (H.E.A.T.) and an innovative fixed table design, operators can expect faster machining speeds on even the most difficult cutting applications and larger workpieces.”

The U1310 offers X-, Y- and Z-axis travels of 1310 mm by 1010 mm by 520 mm, and is optional with a larger full stroke 620mm Z-Axis. The standard machine configuration can accommodate a maximum workpiece size of 2000 mm by 1600 mm by 500 mm and maximum workpiece weight of 6,000 kg. Other features of the U1310 include a programmable 3-sided drop tank system for increased accessibility during workpiece loading and part setups, a fixed table for superior machining accuracy, and Makino’s intuitive Hyper-i control for improved operator efficiency and performance.

Ease of Operation
The U1310 is one of the world’s first large machines to feature a programmable 3-sided drop tank system, enabling excellent accessibility and easy setups for large workpieces and improving ergonomics for machine maintenance and operation. Operators can lower the work tank for unobstructed access from three sides, and can drop the tank below table level for even more accessibility. Additionally, since the work tank height can be adjusted to match the workpiece, the operator can clearly see the machining condition at all times. To reduce the operation interval for wire spool replacement, the machine is standard with a large capacity wire spool unit that accommodates spool size up to 30 kg.

Equipped with Makino’s advanced Hyper-i machine control, the U1310 provides a more intuitive operation experience by utilizing a user-friendly interface similar to that found on tablets and Smartphones. A high-definition touch-screen display features Pinch, Swipe and Spread functions and integrates on-board digital manuals, intelligent help functions, and an e-Learning training system for easy, efficient operation. The Hyper-i control can also be customized to individual operators and/or for certain shifts, and an optional dual display screen can be configured for use with an optional onboard CAD/CAM system.

Superior Accuracy and Precision
The U1310 maintains superior machining accuracy with a fixed work table design that provides excellent machine rigidity, even when the table is loaded with a heavy workpiece. The combination of machine rigidity with machining technology and control software delivers exceptional roundness, and operators can expect shape accuracies within ±3 μm and a best surface finish of 0.3 μm Ra / 2.2 μm Rz.  The machine is also capable of operating wire sizes of 0.200, 0.250, and 0.300mm diameter.

Accuracy is also ensured by the U1310’s dielectric fluid cooling unit, which has been integrated into the base machine casting and keeps the temperature inside the machine at the same level as the dielectric fluid temperature. This provides greater thermal stability, reducing distortion and ensuring stable high-machining accuracy even during long hours of machining.

H.E.A.T. Configurations
The U1310 is available with H.E.A.T. configuration, featuring Makino’s High Energy Applied Technology. This configuration incorporates a combination of flushing enhancements and special generator upgrades that greatly increase cutting speeds on the most difficult machining applications. H.E.A.T. technology is designed to provide unparalleled wire EDM machining speed and accuracy in parts featuring poor or difficult flushing conditions. This performance enhancement enables up to 43 percent faster machining times and up to 33 percent reduction in wire consumption, compared to previous technology.
 

At CMTS 2015, GF Machining Solutions will showcase machines from its high-speed milling and versatile wire EDM product lines in Elliott Matsuura Canada’s exhibitor space, which encompasses booths 2149, 2160, 2348 and 2360. Attendees to the space can expect to see the Mikron HSM 500 MoldMaster, Mikron HSM 600U LP and AgieCharmilles CUT 20P in action.

Mikron high-speed machining centers are typically 10 times faster than conventional milling machines in terms of cutting speed. They also have the wherewithal to achieve greater accuracy and better surface finishes. With more than 10 models in its HSM series, GF Machining Solutions is able to meet the demands of moldmakers and precision-based part manufacturers across all industry segments.

The company developed the Mikron HSM 500 MoldMaster (MM) high-speed milling machine with today’s mold and die makers in mind. As an all-in-one production system, the machine’s specific features and capabilities give shops the versatility to produce a wide scope of mold and die related components –from 58 Rc steel mold cores to hot pressing dies and even sinker-EDM electrodes for intricate mold cavities – all with one machine tool.

In terms of large, complex parts production, GF Machining Solutions upped the ante when it added the Mikron HSM 600U LP to its high-speed options. The linear performance (LP) milling center processes workpieces in a true 5-axis simultaneous high-speed fashion via linear motor technology in the main machine axes and optimized direct-drive motors for the B and C axes. The machine’s 36,000-rpm vector spindle promotes excellent surface finish and part detail, while reducing machining time for semi-finishing and finishing operations.

The AgieCharmilles CUT 20P is one of more than 20 options in the company’s versatile wire EDM portfolio. As a general-purpose machine, the CUT 20P brings high levels of flexibility and low energy consumption to shops using wire diameters from 0.006″ to 0.12″. The machine comes standard with 0.10″ wire guides, while 0.006″, 0.008″ and 0.012″ wire guides are also available. Furthermore, the machine’s low-maintenance, reliable wire threading system boasts autonomy and reduces operating costs.

GF Machining Solutions’ global installed machine base hit 100,000 in June. The milestone further confirms the solution provider’s commitment to delivering the value its customers have come to expect.

With a complete portfolio of Milling, electrical discharge machining (EDM), Laser, Spindle, Automation, Tooling and software solutions and the world’s most comprehensive Customer Services offering, the Division GF Machining Solutions of Georg Fischer continues building on a long legacy of customer-centric innovation.

That legacy reaches far back into history, and includes Mikron AG’s introduction of the first rounding up tool for fine wheels in 1910, Charmilles’ development of the world’s first industrial electrical discharge machine (EDM) in 1954 and—the same year—Agie’s development of the AGIETRON AZ4 with pneumatic servo drive for the Z axis.

Legacy of innovation continues
GF Machining Solutions’ tradition of innovation has continued, with the introduction of over 900 machine types and a staggering range of firsts in the machine tool industry: the first universal Milling center, the first numerical control wire EDM machine, the first automatic wire-threading solution, the first Milling machines with a direct drive on all axes in 1982, the first Milling machine line with an automatic tool changer and fully enclosed work area to protect the user, the first standardized computer numerical control for wire and die-sinking EDM,  the first true high-speed machining center, the first robot integrated on a die-sinking EDM machine, iQ technology for lowest electrode wear, and the world’s largest and most affordable Laser texturing solution.

Today, GF Machining Solutions’ installed base includes 65,000 machines in Market Region Europe, 20,000 in Market Region Americas, and 15,000 in Market Region Asia. The GF Division’s biggest market is Germany, followed by the United States, Switzerland and China.

The Machine Spindle Protection smart machine module “MSP” for GF Machining Solutions’ Mikron HPM 600U and HPM 800U has earned the most prestigious Swiss technology innovation award in the field of manufacturing and production. The PRODEX award was presented during the PRODEX trade fair, a specific event for machine tools, tools and production equipment, this month in Basel, Switzerland.

With MSP, GF Machining Solutions has engineered a revolutionary spindle protection system that delivers considerable added value for customers by eliminating spindle damage, mis-aligned machine geometry, machine downtime, and their related costs in case of unwanted, unexpected spindle crashes.

The winners were selected by a panel of seven experts including representatives of university and industry associations, exhibition management, SMM Schweizer Maschinenmarkt, and MSM Le Mensuel de l’industrie magazine. Nominated products and processes were subjected to a thorough, independent evaluation, and only three prizes were awarded.

MSP delivers value
The MSP smart machine module, available since April 2014, has garnered plenty positive attention not only at PRODEX, but at the 2014 International Manufacturing Technology Show (IMTS) in the United States and at the 2014 AMB international metalworking exhibition in Germany.

To understand the value of MSP, it is important to recognize how it operates:

Collisions mostly occur when a new computer numerical control (CNC) program is executed for the first time. MSP protects the machine and spindle during the setup process. With the MSP, the spindle is able to absorb axial and lateral displacements in case of spindle crashes. The MSP restores a perfect accuracy once the spindle returns to normal operating conditions after the crash.

During the set-up, the machine operates in safe mode with reduced feed rates that allows common cutting operations. The combination of MSP and reduced feed-rates ensures that the spindle and machine are protected against crash-related damage.

In production, fast feed rates are required, and the machine switches back to standard mode and can move the axes at full speed. The MSP secures protected machine geometry, reduced machine downtime, full cost control, reduced machine breakage insurance costs, and calcu­lable machine availability.

The always active MSP smart machine module is supplied with the 20,000 min-1 HPC 190 motor spindle built by GF Machining Solutions’ spindle manufacturer Step-Tec.

Makino announces its new HS-Rib high-speed Z-axis technology for improved speed, lower electrode wear and more uniform finishes in large sinker EDM processes. When it comes to reducing sinker EDM cycle times, it is not the maximum jump speed that is important, but rather the acceleration speed. Makino’s new high-speed Z-axis technology has a jump rate four times faster and Z-axis acceleration rate 30 times faster over previous technologies. This capability produces a more efficient hydraulic effect during machine processing, which helps evacuate debris from the spark gap, even in deep-rib features.

“As with all machining processes, there’s an insatiable desire to reduce cycle times while meeting part-quality requirements in sinker EDM processing,” said Brian Pfluger, Makino’s EDM product manager. “Fulfilling these needs involves a number of considerations, including how to process for best speed and efficiency, minimize electrode manufacturing requirements, and reduce electrode wear to achieve the best possible surface finish quality. Our new high-speed Z-axis technology, combined with Makino’s SuperSpark IV, helps support these factors, providing an ideal balance for efficiency in both electrode consumption and cycle times without the need for external auxiliary flushing.”

The new high-speed Z-axis technology is available on all Makino EDNC-Series sinker EDM machines, and is designed for use in large workpiece applications requiring high accuracy and fine surface finishes. Its design offers highly flexible processing capabilities, including a jump rate of 20 m per minute with 1.5-G acceleration, Z-axis strokes ranging from 500 to 800 mm, and programming of orbital machining patterns with no amperage limitations. The use of direct-drive motor technology and liquid cooling within the Z-axis structure ensures sustained thermal stability and precise depth control, and supports electrode weights of up to 100kg (220 lbs.).

Makino also offers the following four process strategies for optimal performance based on users’ unique requirements for speed, surface quality, accuracy and electrode wear:
Low Wear Settings: Provide a single-electrode rough and finish process
Advanced Orbit and Jump Settings: Improve machining speeds and surface finish consistency
High-Speed Z-Axis: Improve machining speeds and accuracy
Aggressive Power Settings: Optimize machining speed (sacrifices electrode wear)

Makino EDNC-Series Sinker EDMs
Makino’s EDNC-Series sinker EDM machines combine rigid and precise construction, simple programming and advanced performance features for accurate EDMing of large workpieces. Equipped with the new high-speed Z-axis technology, these large, heavy-duty machines can produce deep ribs as fast as, or faster than, the smallest sinker EDM machines on the market. Automatic tool change and adaptive controls enable high levels of unattended machining without the need for operator intervention, and is further supported with advanced automatic jump machining controls to optimize debris removal without the need for external flushing.

EDNC sinker EDMs are designed with several friendly and efficient features. The machine uses a space-saving design that incorporates the dielectric reservoir into the base casting, which saves on floor space while also improving the thermal stability of the machine. Most EDNC-Series machines have a full three-sided programmable drop tank with unparalleled ergonomic access to the machine for setups and operation. All machines feature fully automatic fire-suppression systems, and use a special UV sensor that affords an excellent first line of defense for added operational safety. Programming can be performed using the menu-driven touch screen advanced model plan or streamlined MPG conversational format systems. Both methods offer simple selection of machining conditions for workpiece and electrode material type, and the desired feature shape and surface finish. The machine also is designed with advanced menu-driven 2-D and 3-D orbital motion techniques that provide high accuracy and uniform surface finish results over the entire workpiece detail regardless of complexity.

All EDNC-series sinker EDMs can be equipped with Makino’s proprietary High-Quality Surface Finish (HQSF) technology that yields achievable surface finish capabilities 50 percent better than that of conventional surface finishes, regardless of discharge surface area. Even when machining to standard/conventional surface finishes, the HQSF technology can yield a double-digit saving in cycle time.