In 2018, the mould-making department at Procter & Gamble optimised its portfolio to meet requirements for multi-cavity moulds that need small, high-accuracy geometries. In addition, the company wanted to continue its changeover from copper to graphite electrodes, which began in 2014. With the investment in OPS-Ingersoll’s Eagle G5 Precision die-sinking EDM machine, which is available in the UK from the Engineering Technology Group (ETG), Proctor & Gamble has fulfilled this task. Now, the company has numerous options for making the manufacturing processes more efficient and economical, while having the ability to tackle new challenges.

Prototyping and tool-making activities at Procter & Gamble focus on dry and wet shavers as well as manual and electronic toothbrushes. To meet high interchangeability and accuracy demands, the Kronberg plant in Germany was looking for a new die-sinking EDM machine.

“After a short benchmarking exercise, we realised that there was no machine on the market that was comparable to the Eagle G5 Precision,” states Jürgen Mohr, group head of innovative prototype and moulding technologies. “We’ve found that the quality characteristics of the G5 Precision have enabled us to meet our requirements for high precision in multi-cavity moulds and high-quality surfaces.”

With optimal process reliability and the fact that it is no longer necessary to intervene in the process to optimise the erosion technology, Proctor & Gamble can now manufacture parts with an accuracy of less than ±0.01 mm in a fully automated process. There are enough examples in Kronberg that speak for the use of EDM, including mould cores with a clamping length of 250 mm that tend to vibrate during milling. Where these parts used to be milled and partially eroded, they are now finished in a single EDM operation on the G5 Precision.
For further information www.engtechgroup.com

At the recent MACH 2022 exhibition in the UK, NCMT showcased the Makino U6 H.E.A.T. Extreme wire-cut EDM centre. In addition to using standard wire from 0.1 to 0.3 mm, NCMT says the machine is optionally able to run the largest diameter wire – 0.4 mm – of any machine on the market. The wire is coated and distinct from the uncoated brass wire that is commonly used in industry.

The extra wire thickness, together with the use of a second booster generator in the machine, allows 2-3 times higher productivity and heavier duty machining compared with using a standard 0.25 mm wire. Thicker wire also allows a slower unspool speed, so there is no increase in wire consumption rate. The demonstrations on the NCMT stand focused on the machining of a tall keyway, together with a comparison of machining with 0.4 mm wire and other diameters in a set time, assisted by dual pumps delivering high pressure and volume flushing.

Part of Makino’s U-series wire EDM machine platform, the U6 H.E.A.T. Extreme uses a new Bedra copper core wire featuring a double-layer coating with controlled zinc donation. The wire has been optimised for use with Makino’s generator and is exclusive to the new machine, promoting fast cutting at a reduced wire speed, leading to lower manufacturing cost. Areas of application include aerospace and medical component machining, separating additively manufactured parts, machining tall moulds and dies, and tackling tough nickel alloys.

The U6 H.E.A.T. Extreme also features Makino’s HyperDrive Extreme wire control to raise speed and performance. The system employs servo-motor tensioning that provides both jet and jet-less automatic threading modes, and expands the range and stability of wire tension to overcome the difficult job of reliably threading high tensile strength (stiff) wire.
For further information www.ncmt.co.uk