FEATURE ON EDM

VHybrid from Vollmer offers ultimate flexibility

Among the latest innovations presented at the recent GrindingHub exhibition, the new VHybrid from Vollmer was one of the talking points of the show. With the facility to both erode PCD and grind carbide cutting tools in a single operation by combining the two technologies into a single machine, the VHybrid is the epitome of flexibility.

To celebrate the arrival of this innovation and develop a greater understanding of the concept, Alexander Schmid, product manager for rotary and PCD tools at Vollmer, discusses the new arrival in more depth.

“We started with two technologies, disc and wire erosion technology,” he says. “With this technology, we have significant success processing tools via erosion. The concept for the new VHybrid machine is borne out of the successful VGrind technology. This means that we have vertical spindle alignment with the upper spindle being the grinding spindle, and the lower spindle having both erosion and grinding. With this functionality, we can erode and grind most of the tooling that is available on the market. Furthermore, as the use of complex tools such as full-head PCD tools is steadily increasing, the demand for machines that enable combined machining, eroding and grinding, is also growing.”

The concept of the VHybrid 260 offers the user the possibility to erode 100% but also to grind 100%. This is a decisive advantage as both technologies are available for use on the same tool. But the machine offers many further benefits besides.

“For instance, the generator in the VHybrid machine is the most powerful in an erosion machine on the market right now,” says Schmid. “We have received feedback from the market that our system is the benchmark in terms of efficiency and surface finish.”
For further information www.vollmer-group.com

Wire EDM upgrade: fit for the future

A series of upgrades for GF Machining Solutions’ wire EDM machines will future-proof their performance, says the company. The upgrades relate to the CUT C, E and P wire EDM ranges, increasing their productivity, functionality, autonomy and process reliability.

For instance, with the Turbo Tech upgrade, customers can improve their processes and achieve higher quality and productivity. By applying the upgrade, the machine is provided with an additional technology priorities option – a compromise between speed and accuracy – in good or bad flushing conditions. Productivity can increase from 10% to 40%, depending on the geometry of the part and the flushing conditions experienced.

If customers need additional functionality they can enhance their machines with the Taper Expert upgrade (pictured), which enables the machining of large taper parts.

Customers can also increase the autonomy of their machines. One example is the big spool upgrade (up to 25 kg wire), which ensures longer process continuity with no need for constant wire changes.

In addition, users can take advantage of GF Machining Solutions’ rConnect platform, which comprises three digital services: rConnect Customer Cockpit, rConnect Live Remote Assistance and rConnect Messenger. With the ultra-secure hotline, rConnect Live Remote Assistance, customers benefit from the personal support of GF Machining Solutions’ qualified experts, while the rConnect Messenger app allows them to gain remote access to their machines and receive status updates on their mobile devices.

Thanks to the recently developed Seamless Support, a new module in Live Remote Assistance, customers are able to generate their service requests or ask questions about applications directly from their control system.
For further information www.gfms.com/uk

PECO fast-tracks another Sodick machine

A manufacturer of products for model railway enthusiasts has placed an order for another Sodick EDM machine. Devon-based PECO, which supplies its products to model shops across the UK and around the world, is about to enhance its toolroom with the addition of a Sodick ALC400G ‘i Groove edition’ wire-erosion machine from Sodi-Tech EDM. It will join three existing Sodick machines on site.

Established in 1946, PECO (Pritchard Patent Product Co Ltd) has its headquarters and manufacturing plant in the picturesque Devon fishing village of Beer, where the 150-employee business produces model rolling stock and track across eight different scales (from Z to G), as well as lineside/scenic and electrical accessories. Manufacturing in-house is clearly important to this progressive business, which is why the company runs a fully equipped tool room.

With its existing Sodick wire EDM passing a decade of service – and despite its ongoing excellent performance – PECO decided it would be prudent to look at a second wire-cut model.

“It was only ever going to be another Sodick,” states innovations manager Paul. Hitchcock. “Not just because of machine quality, accuracy and ease-of-use, but also the support and relationship we have with Sodi-Tech EDM. We saw a press article about the Sodick ALC400G with its ‘i Groove’ rotating wire mechanism and decided to undertake some trials.”

Applying rotation to the wire reduces wire consumption and allows the constant use of new wire surface for enhanced finishing and accuracy from the top to the bottom of the workpiece. This capability brings further peace-of-mind regarding precision and reliability, which is vital to a busy company such as PECO. The plant works a single shift but often leaves its Sodick machines to run overnight unattended.
For further information www.sodi-techedm.co.uk

PP C&A signs new Winbro deal

A strategic manufacturing outsourcing specialist has signed a major new deal to support the development of a UK-built EDM drilling machine. PP Control & Automation, which employs over 230 people at its facility in the West Midlands, will assemble the EDM generator module that forms the heartbeat of Winbro Group Technologies’ new HSD-351 model.

A new production cell manned by eight PP C&A experts has been set-up to complete the build, with work on the first 25 units set to begin shortly for use in drilling holes in complex aerospace and industrial gas turbine blades and nozzle guide vanes. It is a mutually beneficial relationship that has spanned a decade and 10 different model variants, with the decision to outsource continuing to provide production ‘flex’, reduced assembly time and improved supply chain management for the Leicestershire-based firm.

Tony Hague, CEO of PP C&A, says: “If you’re going to write a book about strategic manufacturing outsourcing and how it can work, I’d like to think this relationship would be in the case study section. To work with a company that operates in such a demanding field for 10 years is some achievement, and we’re delighted to be entering our ‘testimonial year’ with a new machine tool to help them build.”

He continues: “The HSD-351 is an EDM machine that packs so much power in so little space and we have been instrumental in helping produce the heartbeat of the model – the EDM generator module.”

With a footprint of just 2.5 sq m, the HD-351 boasts a capacity of almost 700 electrodes across a range of diameters.
For further information www.ppcanda.com

Up to 20% faster processing speeds

GF Machining Solutions recently supplied a new wire EDM machine to Bedestone Ltd, a wire erosion and jig-grinding specialist based in Birmingham. The machine, an AgieCharmilles CUT P 550 Pro has taken its place alongside two, previously acquired, large-capacity wire EDM machines and two EDM hole drills, to create a flexible, responsive and high-precision wire EDM resource for its growing customer base.

Says co-owner and director, Richard Stanley: “The new machine has replaced an older Charmilles 330F wire eroder which, while still able to meet our accuracy and surface finish requirements, was relatively slow by today’s standards and was experiencing some reliability issues that, if left unchecked, would likely impact on our ability to meet customer lead times in the future.”

He continues: “We spent time identifying the key features and characteristics of the new machine we needed and approached a number of EDM machine tool manufacturers with our plans. We had also devised a challenging test cut [machining a precision spline] that we asked the participating machine tool manufacturers to undertake.”

The key performance indicators of the test cut were part accuracy and cycle time. On both measures, as it transpired, the CUT P 550 Pro wire EDM machine from GF Machining Solutions came out on top.

Says Stanley: “The CUT P 550 Pro was the best performing machine in the test cut, but our decision wasn’t just based on the results of the test. We also liked and responded positively to the business approach adopted by GF Machining Solutions. From the outset they were interested in what we were doing and where we wanted to get to. It felt more collaborative rather than merely a supplier providing a new machine to a customer.”
For further information www.gfms.com/uk