Sodick Unique 7-Axis EDM Solution Draws the Crowds at EMO
2009-10-21
Sodick has once again launched a world-leading technology to solve its customers' most difficult machining problems - this time a 7-axis "turn and burn" EDM die-sink solution that controls the movement of a twisted electrode so that it penetrates the workpiece in a corkscrew-like motion - an increasingly frequent requirement for advanced applications, particularly in the aerospace, power and medical sectors.
The machining of components with this type of complex geometry has up to now only been possible with 5-axis milling applications - and then only in the open-channel form. Sodick's latest innovation opens up a wide range of manufacturing opportunities, as these closed-channel forms reduce the loading on the blade walls as well as reducing the wear on pump rotors and seals - and all at a fraction of the cost of milling, particularly when working with "super-alloys" and when the "nano-wear" capability of the Sodick generator is taken into account.
Sodick Working with Jauch-Schmider
The design of the latest generation of turbine and pump rotors poses many manufacturing challenges including the resolution of the conflicting pressures of simultaneously increasing power output while reducing emissions. This has resulted in designs incorporating the transportation of more aggressive and higher volumes of gas and steam, which has therefore driven the development of ever-more resistant alloys - which are, naturally, more difficult to machine.
EDM die-sinking has long been established as the ideal manufacturing process for this type of machining work - but until now it has been unable to tackle the required complex geometries. To overcome this, Sodick has worked closely with specialist technology provider, JauchSchmider, www.jauchschmider.com, developing the brand new Multiple Erosion Head, which, although it has already been successfully installed in aerospace manufacturing operations, has been publicly demonstrated for the first time at EMO 2009.
This winning combination of the JauchSchmider's Multiple Erosion Head and the Sodick AG60L provides the perfect solution for the production of complex 3-D cavities, as the Sodick multi-axis controller rotates and controls the movement of 7 axes simultaneously. Furthermore, the single set-up operation increases productivity and reduces the possibility of human error, a key benefit when manufacturing such high-value, critical components.
5th Generation Linear EDM Solutions
The AG60L is part of the new 5th generation of linear EDM solutions from Sodick, which includes a range of both wire and sink machines.
The AG400L and AG600L wire models have been developed to achieve even higher precision, easier operation and higher cutting performance, while, of course, maintaining Sodick's ECO credentials. With their three-sided rise and fall tanks and four-sided enclosed worktables these machines provide ample set up space while being suitable for automation. Other advances include automatic dielectric level, enhanced anti-rust and anti-corrosive properties and upgraded performance through the incorporation of Sodick's DSM (Dynamic Shape Master) system to increase cutting stability in stepped areas, pockets and through-holes.
The new die-sinking range includes the AG40L, AG60L and AG80L, which incorporate a new active control system which simultaneously performs both discharge control and motion control through its high speed communications controller. The new SGF2 generator provides much increased machining speed - up to twice the previous rate with graphite electrodes, and this is linked to a significant reduction in electrode wear - to levels Sodick describes as "nano-wear". The die sinkers have been designed for ease of access and operation and automation, while dielectric filling and draining time has been much reduced to decrease set-up time.