Increasing Productivity

With the trend toward direct carving on machining center, the machining performed by die-sinker EDM requires increasingly localized and precise surface roughness, and it has become possible to configure a machining process using multiple compact electrodes. This has increased the frequency of electrode change, requiring operator intervention that reduces the operating rate. This is one factor resulting in longer lead times.

The solution we propose is to automate the compact electrode and workpiece (*1) change work. By combining a robot with the die-sinker EDM that you currently use (*2), it is possible to eliminate wasted waiting time at the electrical discharge machining process and help shorten delivery periods. By operating the unmanned robot system late at night, on holidays, and at other times outside business hours, it is possible to perform continuous long-term operation. Utilizing jigs is also an important point in order to maximize accuracy in unmanned machining. With the SR12 robot that we introduce here, the rack interval and jig type can be flexibly changed, allowing construction of a system that supports the customer’s jigs and electrodes. Because it can also be connected to a control system or IoT devices, it is possible to continually improve the level of automation and achieve steady improvements in productivity.

*1: Please consider the SRC80 for large-size workpieces. See here for details.
*2: Supported by Sodick AP1L, AP30L, AL40G, and AL60G Die-sinker EDM.

With wire discharge machining, it is necessary to increase the machining count and eliminate surface unevenness in order to achieve more precise surface roughness on the cut surface. Initially rough machining is performed with machining speed taking priority, and finally the machining energy is reduced and finishing is performed to produce the final shape accuracy for surface roughness. Adjusting these kinds of machining conditions requires expertise. In manufacturing workplaces where the problem of personnel shortage is becoming increasing severe, this work is becoming increasingly difficult. In order to resolve these problems, we developed the AL400/600G i Groove^⁺ Edition wire-cut EDM that includes Digital HF Control – a new technology for Sodick.

Previously the machining speed was decided based on the average voltage during machining. However with the AL400/600G i Groove^⁺ Edition that is introduced here, digital monitoring is performed continuously during machining in order to maintain the optimal discharge conditions. Because it is resistant to the effects of external disruptions (changes in water quality or changes in workpiece sludge density), it is not necessary to adjust the machining conditions, and machining at the optimal speed can be easily performed by any operator, producing a high-quality machined surface. This can be expected to shorten machining times and make it possible to aim greater production increases than ever before.