No-flush, Zero-electrode-wear Technology

July 6, 2010

Sodick’s new AG40L , AG60L, and AG80L linear-motor-driven, CNC sinker EDMs feature no-flush and zero- electrode-wear technology. The high axes speed and fast acceleration of the series create its own natural flushing condition.

The up-and-down motion of the electrode creates a pumping effect, sweeping out the eroded particles, gas, and tar from the spark gap. Machining results do not vary depending on the operator‘s experience, and there is no need to machine flush holes into the electrode or to set up auxiliary flushing ports.

The new zero-electrode-wear circuit comes standard on these sinker EDMs. According to the company, this circuit allows steel to be cut with virtually zero electrode wear when using graphite or copper electrodes.

Less electrode wear results in sharper part detail and decreased electrode usage, which saves on production costs and reduces errors normally associated with multiple electrode preparation.

The circuit reduces graphite electrode wear to less than 0.1 percent while increasing machining speed by as much as 20 percent, the company reports. The ability to minimize wear is made possible by the control technology, which stabilizes the use of extremely high discharge on times.

The X, Y, and Z linear-motor drives are coupled with a 1-µm Heidenhain absolute glass scale feedback system. This enables precision cutting and positioning accuracy. With the new absolute linear glass scales, the true machine position is always known. It also reduces setup time since the operator no longer has to “home” the machine after it has been powered down.

These EDMs also have been designed with Sodick’s new Environment Adaptation System. Machine temperature is stabilized by circulating air inside the column. Insulation covers the entire column and prevents the outside air from affecting the temperature inside the column, which improves the machine’s thermal stability.

The EDM’s control is Windows®-based and comes standard with a 15-in. LCD touchscreen. The LN Assist screen prompts the operator to input the necessary cutting conditions such as electrode shape, material, cutting depth, and required surface finish. The control will input the best cutting conditions and offsets and automatically write the NC program.

The AG40L has 16- by 12- by 11-in. travels; the AG60L has 24- by 17- by 15-in. travels; and the AG80L has 34- by 21- by 17-in. travels.

All machines come with a three-sided rise/fall worktank, which provides easy access for workpiece setup. The dielectric oil is automatically set by the tank height. The worktank can be programmed to rise and fall to allow a robotic arm to reach inside the tank to load and unload a workpiece or electrode. Automatic tool changers, a C axis, and robots can be added to the machines to maximize production.

For more information, visit www.sodick.com.