GF Machining Solutions has recently introduced four features to its latest generation of wire EDM machines: Intelligent Spark Protection System (ISPS) for monitoring spark distribution along the wire; iWire to optimise and reduce wire consumption; Uniqua, the company’s new HMI for EDM machines; and TurboTech, new standard technology that is faster than the existing speed technology on its wire-cutting EDM machines.

Essentially, the new ISPS module analyses sparks and clearly defines their concentration. As a consequence, it is possible to adjust machine parameters accordingly (in real time) to prevent wire breakage and maintain optimal cutting speed. The process is automatic and effective, especially when experiencing difficult cutting conditions and, as a result, users can eliminate machine downtime and process interruptions.

iWire is a sustainable, intelligent process that helps to optimise and reduce wire consumption. As an adaptive software module, iWire comes into its own when individual workpieces ready for machining present big variations in height or when the upper and lower heads cannot be placed close to the surface of the workpiece. The module helps reduce wire consumption rates by up to 40%, as well as wire costs.

According to GFMS, the Uniqua HMI is powerful and intuitive, helping customers to improve their productivity, determine and re-order their machining priorities and ultimately get the most from their wire EDM machines. Uniqua adapts to the customer’s way of working. Integrated on-board help and tutorials are always available, making it easy to use, not only for operators accustomed to ISO programming, but also for relative novices.

TurboTech offers an excellent speed-accuracy compromise in good or bad flushing conditions, is available for all wire types, and is fully integrated in Uniqua or AC Cut 2 interfaces.

For further information
www.gfms.com

Cutting tool manufacturers have always had the inconvenience of producing solid carbide and PCD cutting tools on two separate machines. Now, however, Vollmer has eradicated this issue with its flexible new VHybrid 260 solution that can grind carbide tools and erode PCD tools on a single platform.

Importantly, the VHybrid 260 allows users to switch between grinding and erosion processes in next to no time. Utilising Vollmer’s multi-layered machining technology, the vertical alignment of two spindles is a novel arrangement that allows the grinding and electrode wheelsets to pivot the C axis precisely, ensuring operators always achieve optimal results. If the tool requires both grinding and erosion, the VHybrid 260 can create one complete and efficient machining process for all tool production requirements.

The multi-layered spindle configuration allows the grinding of carbide tools with diameters of up to 150 mm on the top spindle, whereas the bottom spindle can accommodate both grinding and erosion. This design enables the machining of carbide or PCD tools up to a diameter of 150 mm thanks to the high-performance and finely tuned Vpulse EDM erosion generator. The generator delivers surface finishes to roughness of 0.1 μRa, while electrode calibration and wear control combines with a dressing device to provide fully automated processing.

Vollmer says that quality is built into every facet of the VHybrid 260, demonstrated by the company’s ‘wall concept’, which provides high rigidity and vibration damping through its concrete polymer foundation. This is complemented by spindle and motor cooling technology that creates thermal stability, while the vertical spindle configuration eradicates issues related to fixing and floating bearings.

For further information
www.vollmer-group.com

As part of the Volz Group, Volz Engineering Ltd has ambitious growth plans. The Rochdale-based company has recently invested in a new CMM, two three-axis machining centres, a turning centre and, most recently, a Mitsubishi MV2400S wire EDM machine from the Engineering Technology Group (ETG).

Volz Group produces HVAC filters for commercial and industrial applications, and manufactures the machinery for producing the filters and associated components like filter frames and clips.

Managing director Alan Reeson says: “EDM is an integral part of our business as it services both the press tool and automated machinery departments. The outstanding service and support ETG provided for our previous 25-year-old Mitsubishi machine was why didn’t need to look elsewhere for a new machine.”

The new MV2400S provides a “night and day” contrast to the company’s previous wire EDM machine.

“First and foremost, the new Mitsubishi can run lights out giving us 24/7 production,” says Reeson. “We currently run one shift, but the facility to set the machine up to run unmanned overnight is a huge advantage. This is credit to the wire having the facility to re-thread and re-position itself automatically and continue working, so the machine doesn’t lose production hours if the wire breaks. Additionally, the set-up time is 60% faster on the new Mitsubishi MV2400S than the previous machine. We are now setting up and running jobs in less than one hour. More impressive is that as part of the training programme from ETG, the ETG engineer ran through ways to set up existing jobs differently to how our shop floor staff have previously done things. As we do a lot of repeat work, this further improves our processes, productivity and throughput.”

For further information
www.engtechgroup.com