Taking die-sink EDM to the next level

To enhance the manufacture of technically challenging moulds from hardened stainless steel, Ledwell Plastics has invested in a new Sodick AD35L spark erosion machine from Sodi-Tech EDM. This advanced die-sink EDM machine provides the speed and accuracy required to reduce costs and enhance precision, while also offering low electrode wear and the necessary reliability to facilitate unmanned overnight operations.

“Our toolroom makes moulds from many different materials, everything from aluminium through to hardened stainless steel,” explains managing director Benn Simms. “Recently, however, we were working almost exclusively with the latter material in the production of very small and intricate moulds, a trend that looked set to continue for some time. The problem was our existing die-sink EDM capability, which was somewhat antiquated, meaning we had issues with accuracy and breakdowns that were impacting project timescales and costing a lot in repairs.”

As a result, Ledwell Plastics sought a new die-sink EDM that could work to tolerances of less than 0.025 mm. In addition, the highly technical, hardened stainless steel moulds require a large amount of sparking, so fast processing speed was another factor high on the wish list.

“We looked at existing spark eroders, but after undertaking some research and speaking to other Sodick users, we settled on the AD35L,” says Simms. “During an on-site demonstration at Sodi-Tech EDM we could see that the machine’s performance was particularly impressive with its high-speed linear motors.

“Our new Sodick allows us to run overnight, unlike our previous machine, which we could never trust in that regard, particularly with blind components/features that are difficult to flush,” he continues. “The high-speed linear technology of the AD35L evacuates the cavities much better with its enhanced flow of dielectric fluid.”

For further information
www.sodi-techedm.co.uk

Over 60,000 attend EMO 2021

Promoted by CECIMO and organised by UCIMU, the recent EMO Milano 2021 exhibition registered more than 60,000 visitors from 91 countries. Luigi Galdabini, general commissioner of EMO Milano 2021, states: “The exhibition data sets confirm the value of EMO, which is considered a reference point for the worldwide industry of machine tools, robots and automation systems. In such a complicated, historic moment, where the public health emergency is not yet completely over, EMO showed its importance.”

Alfredo Mariotti, director of the exhibition, adds: “A very large number of exhibitors have expressed their full satisfaction with the results achieved over the six exhibition days. ‘Qualified and very motivated visitors’, ‘a duly organised trade show in all its details and not least those related to safety’: these are the most common expressions of appreciation received both from habitual exhibitors at the show and from companies that have not participated previously.”

For further information www.emo-milano.com

High-precision vertical grinders

Superabrasive specialist Engis is releasing its EVG series of high-precision vertical grinding machines for the production of ultra-smooth surfaces. These machines can grind advanced materials to a high degree of precision in flatness and surface quality, greatly reducing or even eliminating the need for subsequent lapping.

Ideal applications for EVG series machines include semiconductor wafer grinding or back-thinning (SiC, GaAs, Sapphire, Si, GaN, AIN, InP), semiconductor equipment components, glass ceramic, as well as substrates for semiconductor packaging, including MEMS (ceramic, polyimide).

Engis EVG machines are available in three different models, the EVG-200, EVG-250 and EVG-300, all of which offer a PLC, 400 rpm work table speed and 2000 rpm max wheel speed.

Advanced machine control options are available, providing automated grinding wheel dressing, automated positioning of the grinding wheel relative to the workpiece and workpiece thickness measurement. For maximum control, an upgrade to in-process thickness measurement with feedback to the grinding cycle in real time is also available.

The most advanced model offers automated thickness options: multi-point contact probing for multiple wafer grinding or a choice of contact or non-contact continuous in-process measurement for single wafer machining.

EVG Series machines are equipped with Engis grinding wheels based on mixed abrasive diamond (MAD) wheel technology, which tailors the wheel to the material in cut. Engis specialist application engineers can provide specific process recommendations for particular materials and applications.

For further information
www.engis.com

Waterjet deburring and cleaning system

With its new high-pressure waterjet deburring system FlexJet HD, Karl Roll GmbH has developed an efficient solution for deburring and cleaning in one work step. Burrs and chips are easily removable, along with welding beads and layers of paint and scale. Individually adapted nozzle systems guarantee a high degree of workpiece versatility and, at the same time, high precision for reproducible results.

Deburring machined components is a challenge due to areas that are difficult to access, such as internal and intersecting holes, deep and small holes, undercuts, and blind holes. Karl Roll GmbH has developed the FlexJet HD series for these tasks. The system enables deburring and cleaning with a water pressure of around 500 bar in one work step.

The rotary table integrated in the treatment chamber of the new system can accommodate components with a diameter of up to 450 mm and a maximum height of 550 mm, while the maximum workpiece weight including the clamping device is 100 kg. These capacities make it possible to handle, for example, an engine block for a four-cylinder engine or several small parts.

For a precise and reproducible result, the workpiece can be rotated during the process as required and moved along the X axis. At the same time, the nozzles can move along the Y and Z axes. It is also possible to direct the water jet flat for deburring and cleaning larger surfaces.

State-of-the-art control technology positions the CNC axes. Users can program the process sequence offline using G-code and a teach-in solution via a 15-inch control panel. There is also the option of programming with a handheld terminal.

For further information
www.karl-roll.de

Real-time information

ND Precision Products (NDPP), an established ISO 9001:2015 accredited company and long-term user of PSL Datatrack production control software, has a stated mission to deliver precise, high-quality tooling to its customers. NDPP has continued to invest in customised PSL Datatrack solutions over the years to help achieve this goal. The latest investment has been in Status Boards: visual displays to provide real-time production flow and order fulfilment information to the shop floor. The Status Boards give shop-floor operators clear visual data on the production status of any job.

For further information
www.psldatatrack.com