With Intelligent Power Generator (IPG) digital technology, the EDM machines deliver ultra-fine surface finishes (Ra 0.1) and can improve cutting speeds by up to 20%, says the company.
Several ‘Expert’ systems further optimise the IPG’s cutting performance, especially when undertaking demanding and challenging applications. For instance, POWER-Expert monitors and changes the power levels required to machine parts with variable heights. This system protects parts from unstable conditions at high cutting speeds. Simultaneously, the system controls spark parameters during finishing operations to provide high-quality surface finishes on variable height parts. This capability maximises part finishes and reduces the need for secondary bench work.
Regardless of workpiece height, another Expert system – WIRE-Expert – is used to control wire wear and achieve continuous geometrical accuracy from all directions.
For part profile accuracy, PROFIL-Expert automatically adapts the machining parameters and cutting path for rough and skim passes to control fine details and ensure positioning and contour accuracies of ±2 micron, while TAPER-Expert technology cuts angles from 0 to 30° (45° as an option) to maximum Z heights.
TAPER-Expert corrects shifts of the Z reference position in real time, even when the taper angle is changing. The taper angle is also held to within 10 seconds on average, providing taper accuracy and geometry reference accuracy throughout the taper cut.
Fixed tables on the machines provide rigidity and stability that ensure accuracy when machining heavy workpieces. Moreover, integrated temperature regulation systems consistently maintain temperatures within ±0.2°C, which guarantees repeatability over long periods of time. However, in machine shops where the ambient temperature may vary throughout the day, a thermo-stability option provides an extra layer of temperature control protection from thermal effects on machine axes.
Cut P machines also feature GF Machining Solutions’ collision protection technology in the X, Y, U, V and Z axes, which prevents potential machine damage and eliminates costly down time and maintenance, even at maximum axis-travel speeds of 3 m/min.
The Windows 7-based AC Cut HMI 2 user interface on the machines simplifies file management and maximises operator efficiency with its 19” touch screen and latest i7 CPU technology. This system also supports intuitive programming directly on the control as well as imported CAD/CAM files with its built-in AgieCharmilles CAM Easy CAD/CAM software. In addition, the EDM series is ready for Industry 4.0 with eConnectivity features that connect the machine to larger shop management systems for effective monitoring and increased machine utilisation.
New automation solutions, including Automatic Slug Management (ASM), Automatic Slug Welding (ASW) and Renishaw probing systems, reduce processing time by up to 20% in lights-out production environments. Additionally, the Cut P series 350 and 550 can integrate with robots such as the System 3R WorkPartner 1+, which automatically loads and unloads parts for a single machine or within a two-machine automation cell.
The machines can handle parts ranging from less than 1 mm up to 800 mm in height, and weighing up to 6,000 kg. Over 600 dedicated, pre-programmed cutting processes are available on-board.
