FEATURE ON EDM

Higher precision and less waste

Anca has made available its LaserPlus system on the company’s EDGe machine. The EDGe is used to erode PCD cutting tools, which in turn are used in the aerospace and automotive industries.

“The LaserPlus technology on our EDGe machine will help customers achieve much better accuracy and reduce waste,” says Anca product manager Duncan Thomson. “It ensures all tools in a batch stay within target tolerances, regardless of external influences such as wheel [electrode] wear or machine growth due to thermal variation. The result is improved tool consistency, quality and reduced scrap tools.”
Anca’s EDGe machine includes its proprietary eSpark generator for optimal PCD erosion results. This means that on the one-wheel spindle, two wheel packs support both erosion and grinding operations. The addition of the LaserPlus further enhances the machine’s capabilities for customers.
First introduced on its tool-grinding machines, the LaserPlus system allows newly ground tools to be automatically measured on the machine using a non-contact Blum laser system. Then if required, compensation is automatically applied to subsequent tools in the batch.
“For customers manufacturing PCD cutting tools, the laser technology provides real value due to the unique challenges involved with the process of electro-discharge grinding [EDG],” says Thomson. “Without touching the PCD cutting edge, LaserPlus is able to measure a cutting-tool feature before the final erosion pass. By doing this operation, the technology can identify any variation, which may, for example, be the result of thermal drift or wear on the electrode, from the nominal size and account for this in the final finishing pass. The result is that the finished tool geometry is guaranteed to be on size.”
For further information www.anca.com

Faster, smarter machining

After the official launch at GF Machining Solutions’ International Solution Days in 2017, the AgieCharmilles CUT P 350 wire-cutting EDM solution was again in the spotlight at the EMO exhibition in Hanover at the end of last year.

Industries such as automotive and electronic components, faced with ever-shorter lead times, strive to increase their flexibility and production efficiency while executing their applications perfectly at the first attempt. The recently launched AgieCharmilles CUT P series represents a leap in terms of productivity with smarter machining, however difficult the machining conditions, says the company.
A significant step toward the increased connectivity of Industry 4.0, this range of solutions guarantees longer tooling life and reduces the need for manual operator interventions; reports GFMS. Users now experience 20% greater machining speed, accuracy down to 2 µm and benefit from having access to more than 600 dedicated technologies.
Visitors also experienced how the Mikron MILL S 400U five-axis electrode milling solution delivers stable precision over long machining periods and reduces, when not eliminating, manual finishing operations.
EMO visitors exploring the flow dedicated to the segment of electronic components also discovered complete solutions for achieving uncompromised accuracy over time. Coming together to address these challenges was the AgieCharmilles CUT 2000 X wire-cutting EDM machine with innovations that include automatic on-board quality control and increased cutting speed.
For further information www.gfms.com

Fanuc puts spring in the stride of toolmaker

Redditch-based Vulco Spring & Presswork, which manufactures electrical installations, brackets, clips, clamps, flanges and wire-formed parts, has invested in a Fanuc Robocut C400iB EDM machine to help produce press tooling for its multi-forming machines and 20-70 tonne power presses “We have older EDM machines on-site but we’ve been struggling to locate the spare parts for these machines,” says production engineer Joseph Draper.

“Reviewing the market for a new EDM, the high-speed automatic wire feed on the Fanuc Robocut C400iB was one of the main reasons we bought the machine. This system will automatically feed the wire through a start hole and then the CNC program will begin to cut the job. Afterwards, this automatic feature will cut the wire, move to the next datum point and then process the next feature or hole. The machine will automatically continue to
process hole after hole, or
shape after shape.
“Previously, we had to manually feed the wire at the start point, start the machine and upon completion we’d cut the wire and move the workpiece or wire to the next point,” he adds. “What this gives us is the ability to leave the EDM work for significantly longer periods without intervention. Furthermore, we can leave the machine to run through the night unmanned and arrive in the morning to finished parts.”
For a manufacturer less familiar with the opportunity for unmanned operation or lights-out production, the Fanuc Robocut C400iB assures the end user with its automatic repair system, which will automatically repair the wire and continue production
For further information www.fanuc.eu

More Fanuc machines installed at Alan Spargo

Alan Spargo Ltd in High Wycombe has chosen to invest in two new Fanuc wire erosion machines. Established in 1975, the company offers two core services: a press tool service and a subcontract machining service, which includes grinding and EDM.

“Despite having 20 years’ experience of working with Fanuc machines, we fully investigated the marketplace when we began looking for new technology,” says director Peter Spargo. “However, the Fanuc machines remained on top, so we stuck with what we knew.”
The company purchased two Fanuc Robocut 600iA wire models, a decision that was heavily influenced by the service, longevity and overall performance of existing Fanuc machines at Alan Spargo. That said, there were additional factors that helped steer the decision.
“When comparing the Fanuc brand against other machines, one important factor was the level of accuracy that could be achieved,” says Spargo. “We do a lot of motorsport work and high-precision, multi-stage tooling, for which accuracy is critical. When operating the new Fanuc machines, we can achieve tolerances of ±3 µm. Another consideration was the reliability of the machines, which makes them ideal for unmanned operations.
“We can monitor the machines from a mobile phone or tablet when we aren’t on the premises,” he continues. “This has been particularly useful for the guys who come in and out over the weekend to keep the machines running. When we are busy, we are probably running the machines for 400-500 hours a week, so uptime is critical.”
For further information www.fanuc.eu

Erodex appoints dedicated export manager

EDM graphite and tooling specialist Erodex has appointed a dedicated export manager after achieving a record 54% growth in export sales. The move follows a string of new contract wins with clients in countries including Israel and the opening of a new $2m tooling facility in Virginia, USA.

Director Steve Rolinson says: “As a result of high levels of demand for our graphite products and tooling solutions overseas, we are looking to continue growing export sales and exploring new markets. We have already seen evidence of this over the past 12 months and we believe that now is the right time to appoint a dedicated export manager.”
In addition to managing the day-to-day operations within a newly established department, Laura Collins will ensure that Erodex fully complies with HMRC regulations and those within the diverse range of non-EU countries to which Erodex exports.
“I have always worked in an international trade environment, primarily in export and with a focus on implementing processes and procedures,” she says. “Export sales at Erodex are growing quickly, accounting for an ever increasing amount of overall turnover, meaning that it makes sense to establish a dedicated export department to manage this work. Different countries come with their own complexities or requirements, and as a team we are now well placed to deal with these and play our part in facilitating the growth in overseas trade during what is an exciting time for the company. I am delighted to be on board and very much looking forward to the future.”
For further information www.erodex.com