FEATURE ON EDM

Achieving High-Precision Keyway Machining in Marine Couplings

Shanghai ANTISHICNC has proposed its 630GS3 mid-speed wire-cut EDM to a UK marine equipment manufacturer seeking to machine keyways in the centre bores of tapered coupling hubs used in marine propulsion systems. 

The customer requires keyway dimensional tolerances within 0.05 mm, with cutting depths of up to 500 mm. Maintaining positional accuracy, symmetry and coaxiality at this depth presents challenges for conventional machining methods. 

The 630GS3 has X- and Y-axis travels of 630 and 500 mm respectively, with a customised Z-axis travel of 500 mm to accommodate the workpieces. Electric pushbutton Z-axis adjustment simplifies setup for couplings of different heights. 

Notably, a CNC C-axis indexing system enables accurate angular positioning to maintain keyway symmetry and alignment with the centre bore, while automatic wire tensioning helps maintain consistent wire conditions during extended cutting operations. AutoCut V10.0 and NCCAD programming software provide workpiece measurement and rotary alignment functions to simplify programming and setup. 

The machine also features a rigid bed structure and worktable capacity of up to 700 kg, providing stable support for large coupling hubs. Optimised pulse power control and cutting parameters for high-strength alloy steels are intended to help maintain dimensional accuracy and surface quality while minimising thermal damage. 

At present, the proposed configuration is undergoing final specification approval, including confirmation of the customised axis travel, electrical controls and software requirements. Once approved, the machine will proceed to manufacture according to the customer’s requirements. 

The project demonstrates how machine configuration and process adaptations can address the specific challenges of machining deep keyways in marine propulsion components, where dimensional accuracy and alignment are essential for reliable assembly. 

More information www.antsmachine.com 

Whitehouse Machine Tools Wins Mitsubishi Electric EDM Agency

Whitehouse Machine Tools is now the sales and service agent for Mitsubishi Electric’s wire-cut and die-sink EDM equipment in the UK and Ireland, expanding its portfolio of CNC machine tools and manufacturing solutions. The agreement brings Mitsubishi Electric’s EDM range alongside Whitehouse’s existing machine tool brands, including Brother, Spinner and Biglia.  

To maintain continuity for customers, experienced specialists Scott Elsmere and Dean Barnes have joined the company, bringing decades of technical sales and applications expertise with Mitsubishi Electric EDMs. Machines like the Mitsubishi Electric MV2400S wire-cut EDM, offer general machining accuracy of 3 µm or better and surface roughness down to Ra 0.3 µm. 

Mitsubishi Electric introduced its first commercial die-sink EDM machine in 1964, followed by its first wire-cut model in 1972. The company has since manufactured 75,000 EDM machines for use across sectors including aerospace, automotive, medical devices and precision toolmaking. Its technology incorporates energy-saving features that can reduce power consumption by up to 40%. 

Whitehouse has also invested in a dedicated, manufacturer-trained service division covering its machine tool brands across the UK and Ireland. The team will provide engineering support, spare parts and applications expertise for Mitsubishi Electric EDM customers. 

Peter Smith, sales & marketing director at Whitehouse Machine Tools, says: “The Mitsubishi Electric EDM range is a natural fit alongside our existing CNC machine tool portfolio, complementing our current manufacturing partners without overlapping processes. The precision, reliability and energy efficiency that define Mitsubishi Electric’s EDM products align perfectly with the standards we set across our CNC technology offerings.” 

He continues: “Our introduction of Mitsubishi Electric EDM to the UK & Irish market is further strengthened by the OEM’s European technical support facility near Düsseldorf, as well as the addition of two experienced UK-based specialists.” 

More information www.wmtcnc.com

CHMER Strengthens Dutch Presence Through Hoffman-Metalcare 

CHMER continues to expand in the European market through its partnership with Hoffmann-Metalcare in the Netherlands. The move further strengthens the market presence and brand visibility of CHMER wire and die-sink EDM solutions across the Netherlands and wider Flanders region. 

Committed to becoming a world-class leader in non-traditional machining technology solutions, CHMER leverages its expertise in precision machining, smart automation integration, flexible customisation, and energy-efficient manufacturing solutions to support industries including mould and die, aerospace, automotive, medical, semiconductor and precision component manufacturing.  

These capabilities help customers address growing demands for high-precision machining, process integration, and smart manufacturing. 

Through Hoffmann-Metalcare’s local sales consultation, equipment implementation support, and technical services, CHMER is able to stay closer to the European market and better understand customer needs. The partnership also enables more metalworking and manufacturing professionals in the region to discover CHMER’s technological capabilities and the value of its solutions. 

As a business, Hoffmann-Metalcare develops, supplies and maintains production lines with machining and non-machining machines for metalworking companies and the broader manufacturing industry. 

CHMER says it sincerely appreciates Hoffmann-Metalcare’s continued efforts in promoting its brand. Looking ahead, CHMER will continue to strengthen its collaboration with global partners and expand its international presence, providing customers worldwide with advanced, reliable and flexible precision machining equipment, non-traditional machining solutions and localised services. 

More information www.chmer.com 

Getting Closer to the Spark for a Smoother Surface Finish

Advances in microelectronics are improving die-sink EDM performance, with compact generators enabling faster machining, more precise spark control and improved surface finishes. 

Since the 1970s, semiconductor technology has transformed electronic devices, and similar progress is changing EDM. Early generators relied on analogue systems that could produce inconsistent sparks and required skilled operators to maintain precision. Modern systems use feedback-driven pulse management to control spark energy and intensity. 

Generator location is another factor in machining performance, explains Martin Spencer, managing director of United Machining UK: “By keeping generator modules cool and close, today’s die-sinking machines achieve a higher level of thermal and electrical stability.” 

Traditionally, EDM generators were housed in separate cabinets, connected to the spark gap by several metres of cable. Modern, compact designs allow the generator to be positioned much closer to the electrode, shortening the electrical path and reducing inductance and capacitance. 

This enables faster, more precise voltage control, improving erosion rates while limiting heat transfer to the workpiece. The result is a smoother surface finish and a reduced heat-affected zone (HAZ). 

On patented die-sinking EDM platforms, compact, high-speed generators can be mounted directly on the Z axis or behind the rear wall of the work pan, just centimetres from the electrode. For mould manufacturers, this configuration can reduce cycle times by up to 20%, while helping preserve workpiece integrity during finishing operations. 

Further developments are likely to combine hardware advances with increasingly sophisticated control software. Artificial intelligence, digital twins, predictive algorithms and adaptive spark control could deliver further improvements in precision and productivity. 

Ultimately, bringing the generator closer to the spark helps manufacturers gain greater control over the EDM process, with benefits for machining speed, surface quality and dimensional accuracy. 

More information www.machining.com 

Tooling, Automation and Software Specialist Unveils New Website

System 3R, which offers extensive solutions for EDM machine work holding and automation, has launched a new website as part of the United Machining Solutions brand strategy, giving each brand its own digital presence and providing access to its products, services and technical expertise. 

The redesigned site features updated navigation to help visitors find information across the System 3R portfolio, including work holding, tooling, automation and production software. 

The portfolio is presented as an integrated manufacturing solution. Notably, the Macro range provides sub-micron repeatability and fast clamping, while the WorkPartner series covers applications from single-machine tending to automated multi-cell production.  

System 3R’s software connects machines and automation systems, providing job management, real-time monitoring and cell communication. The solutions are compatible with machine tools from all manufacturers. 

The website also includes a worldwide locations directory, helping manufacturers in EDM, milling, grinding and additive manufacturing find their nearest System 3R contact, sales partner or service location. 

An events section provides details of upcoming trade shows, enabling visitors to plan attendance and arrange discussions with SYSTEM 3R specialists about work holding and automation technologies. 

Ultimately, the new website reflects System 3R’s focus on connected precision manufacturing, drawing on more than 50 years of experience in work-holding technology. It provides a central point for exploring the company’s solutions, finding local support and keeping up to date with its activities worldwide. 

More information www.system3r.com