Micro-tools are drills and milling cutters with diameters below 0.5 mm. Here, sharpening specialist Vollmer is successfully eroding these delicate PCD tools in a highly precise and cost-efficient way with its VHybrid 260 grinding and erosion machine.

Progress in areas such as medical implants and wearables means that electronic components are becoming increasingly fine and delicate, demanding the use ofever-smaller tools in the manufacturing processes. PCD micro-tools with diameters of 0.45 mm and below are in particular demand for the production of microchips.

The Vollmer VHybrid 260 grinding and erosion machine features Vpulse EDM generator technology, which achieves a surface finish of up to 0.05 Ra when eroding, corresponding to an average roughness of up to 0.24 Rz. In addition, it is possible to produce a cutting edge radius of up to 1.5 µm with the VHybrid 260. This capability eliminates the need for any subsequent grinding or polishing of functional tool areas.

To ensure optimum concentricity of 2 µmmaximum when machining micro-tools, the VHybrid 260 features an insulated tool steady rest, which also makes it suitable for eroding. Furthermore, due to the integrated‘Laser Check’measuring system, required tolerances of ±2 µm are achievable during fully automatic circular machining in a closed-loop process.

The VHybrid 260 is based on multi-layer machining, implemented through two vertically configured spindles. The lower spindle is forboth grinding and eroding. Moreover, the machine can switch up to eight grinding and eroding wheels, including coolant supply, fully automatically. Various automation options are available to enable unmanned operation around the clock.
For further information www.vollmer-group.com

To increase efficiency in the EDM production of contamination-free components, bedra has developed the confreecut ONE EDM wire.

In wire EDM, it is particularly important that component surfaces are free of contamination from foreign materials after production. In conventional wire erosion, the surfaces of the cut component may show residues of copper and zinc, requiring subsequent chemical cleaning. The additional cleaning process increases throughput times and production costs enormously. In the case of component surfaces that are difficult to access, the cleaning effect is also limited or insufficient.

Currently, most machine shops specify EDM wires made of molybdenum or tungsten for such applications. However, these wires carry a high material price. In addition, the wire guides are subject to heavy wear and automatic threading can be problematic, reports bedra.

To increase efficiency in the EDM production of contamination-free components, the company is introducing the confreecut ONE EDM wire, whichbedra says stands for contamination-free and fast machining with low wire guide wear and reduced wire costs. The wire has a high-purity outer nickel coating with optimal layer thickness. Run lengths of up to 60,000 metres per spool permit significantly more autonomous production compared with the usual fabrication of molybdenum and tungsten wires.

Notably, bedra was able to prove in numerous tests that confreecut ONE reduces the copper and zinc contamination, with zinc reduced to almost zero during processing with 2-4 trim cuts. In the process, bedra examined the components for these residues using highly sensitive analysis technology. The companyis happy to advise potential customers on specific erosion applications.
For further information www.bedra.com

ONA not only manufactures a wide range of standard-size EDM machines, it also specialises in the design and manufacture of large models such as the AV130, which has a 10 tonne load capacity as standard (expandable to 25 tonne).

According toONA, the AV130 brings great ideas to life, transforming large-scale projects into simple solutions. Of particular note, the ONA AV130 automatically threads of all types of wires and offers a cutting capacity of up to 800 mm in height. The X-axis travel is 2000 mm, with 1000 or 1300 mm in the Y axis. U/V axis travel is 500 x 500 mm, while the maximum taper angle is 30°.

The company says that the AV130’s high cutting speeds equate to a 30% time saving, complemented by minimum maintenance costs and greater autonomy with wire coils weighting up to 45 kg.

ONA’s versatile modular design of its large wire EDM machines allows more than 20 combinations, providing the ability to work with the largest parts on the market. The machineprovidesusers with speed, autonomy, strength and precision, alongsidegreater execution power.

The company says there are many benefits associated with its AV technology. For instance, the numerical control, designed on the concept of usability, has a 23” touch interface, intuitive and visually friendly menus, applications represented by icons, andreal-time information forgreater control of the EDM process. Furthermore, the new interface displays the workpiece in 3D and allows the operator to rotate and move it according to requirements with a simple tap.
For further information www.onaedm.com

GF Machining Solutions has introduced a new range of wire EDM machines. The AgieCharmilles CUT F series comprises two models (CUT F 350 and CUT F 600), each equipped with the company’s proprietary Uniqua control, ISPS intelligent spark protection system, iWire intelligent functions and RFID smart wire system. Furthermore, at the heart of every machine is the proven high-end IPG-DPS generator.

According to GFMS, CUT F machines deliver improved performance and optimised precision. The range sits in-between the company’s established CUT E and CUT P series’ of wire EDM machines and features the tried and tested SparkTrack technology platform.

The new C-frame machines feature an enhanced design that improves thermal stability and vibration control, resulting in higher part accuracies and superior surface finishes, reports the company. Specific features include axis optical encoders (cooled via the work tank and dielectric fluid) and high-accuracy, high-grade ballscrews that improve positional accuracies.

CUT F machines come with an intuitive iHMI featuring a 19” vertical touchscreen, full keyboard and a mouse. The Uniqua platform interface supports offline and at-the-machine programming, and facilitates sequential and object-oriented programming. The control hasa powerful graphic tool with an integrated CAM system and is compatible with all major CADCAM programs.

Of particular note, the iWire function automatically identifies and adapts the wire speed to changing erosion height conditions during the EDM process and, by sodoing, eliminates wire breakage while reducing overall wire consumption per job – in some instances by as much as 29%.iWire technology works in tandem with ISPS, both of which are accessible from the Uniqua control.
For further information www.gfms.com