With proprietary Intelligent Power Generator (IPG) technology, the EDMs deliver surface finishes as good as Ra 0.10 µm and boost cutting speeds by up to 20% over previous models. Several of the company’s ‘Expert’ systems further optimise the cutting performance of the generators, especially in challenging applications.
The Power-Expert software module monitors and changes power levels when the machine is cutting parts with variable heights. Power-Expert thus protects components from unstable conditions while the machine maintains high cutting speeds. Simultaneously, this system controls the spark parameters during finishing operations to provide high-quality surface finishes on variable-height parts.
Regardless of workpiece height, the Wire-Expert system dynamically controls wire wear to achieve continuous and consistent geometrical accuracy from all directions, says the company.
For part profile accuracy, Profil-Expert automatically adapts the machining parameters and cut path for rough and skim passes to provide control of fine details, and ensure positioning and contour accuracies of ±2 micron.
Taper-Expert technology cuts angles from 0 to 30° (45° as an option) to maximum Z heights. The system corrects shifts of the Z-reference position in real time, even when the taper angle is changing. In addition, the taper angle is held to within 10 seconds on average, providing taper accuracy and geometry reference accuracy throughout the taper cut.
The fixed tables on the machines provide rigidity and stability that aid accuracy when machining heavy workpieces. Moreover, integrated thermal compensation systems consistently maintain temperatures within ±0.2°C, which guarantees repeatability over long periods of time. However, in shops where the ambient temperature fluctuates throughout the day, a ‘Thermostability’ option provides an extra layer of protection from thermal effects on machine axes.
CUT P machines also feature GF Machining Solutions’ collision protection technology (ICP) in the X, Y, U, V and Z axes, which prevents potential machine damage and eliminates downtime and maintenance, even at maximum axis travel speeds of 3 m/min.
The Windows-based AC CUT HMI 2 user interface on the machines simplifies file management and maximises operator efficiency with its 19” touchscreen and i7 CPU technology. CUT-P machines are also ready for Industry 4.0 with e-connectivity features that connect to larger shop management systems.
Newly developed 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 operations, says GFMS. Additionally, the CUT P 350 and 550 machines 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.
Featuring over 600 dedicated, pre-programmed cutting processes, the machines can be used to produce parts up to 800 mm in height, weighing up to 6,000 kg. Wires are available in 0.1, 0.15, 0.2, 0.25, 0.3 and 0.33 mm diameters.