EDM on top FORM

Yorkshire-based precision mouldmaker Ryetools (01751 476020) has recently installed two state-of-the-art FORM 3000HP EDM die-sinking machines from GF AgieCharmilles (02476 538666). The new machines were installed at Ryetools' 16,000 ft2 Pickering, North Yorks, facility during September and October 2010 and are being used to manufacture high precision, complex plastic injection mould tools used in the medical devices, health and hygiene, food and drink, packaging, automotive sectors, etc. Image: A typical mould tool The FORM 3000HP machines were purchased to replace the company's two older Agie Innovation die-sink machines, which, owing to their age (10 years plus) and constant use, had started to become unreliable and sometimes struggled to cope with the high precision features and intricate details that characterise complex and technically demanding mould tools. Other significant issues that influenced Ryetools' decision to invest in the new EDM machines concerned the relatively slow cutting speeds of the Agie Innovations, and the need to reduce excessive electrode wear. "Our older EDM technology was starting to affect our productivity and performance, and, ultimately, our competitiveness, too," reports Darren Hugill, Ryetools' managing director. "We knew that the latest generation of EDM machines, with their superior design and build qualities, their faster and more sophisticated control systems, and their powerful and responsive digital generators, could make a major contribution to our business. And that's why we embarked on the search to replace our older die-sink machines." BEST OF THREE Ryetools approached three EDM machine tool manufacturers and, after the test cut process was completed, selected the FORM 3000HP machines. Image: Intricate components now cut better, faster "There were a number of reasons why we went with the FORM 3000s, over and above the machines' impressive test cut results," Mr Hugill explains. "We liked the large capacity of the FORM 3000 machines (600, 400, 500 mm; X, Y, Z) and the manufacturing flexibility this gave us, enabling the machining of both large and/or multiple smaller workpieces. "Having previously had AGIE machines, we were already familiar with the Agievision Control, so we knew that getting up to speed with the new machines would be relatively straightforward, meaning that we could start getting a return on our investment from day one." Other noted advantages of the FORM 3000 machines were: high cutting speeds; thermally-stable design and construction, allowing +/- 5 micron part accuracies to be maintained; excellent surface finish potential – Ra 0.6 micron; and their integrated automation (automatic tool changers and workpiece pallet changers) – essential to help increase productivity. Image: The FORM 3000 installed at Ryetools Adds Mr Hugill: "We also were attracted by the FORM 3000 machines' IQ [Zero Electrode Wear] Technology, which significantly reduces electrode wear, meaning that we do not need to spend time or resources manufacturing replacement electrodes. IQ Technology has had an immediate and positive impact on our bottom line." Since installation, the FORM 3000s have been working flat out and reports suggest that the new machines have helped reduce cycle times by between 28 – 40%. Box item Up to 30% longer service life The new generation of Mann+Hummel (01732 523533) filters for Japanese and European EDM machines offers machine operators up to 30% longer service life, in comparison to conventional filters, and clean dielectric fluid right from the start. This is possible through the use of a new synthetic media and a triple progressive bellows design in the filter. The product is also available as a stand-alone solution. Image: Up to 30% longer service life, that's the claim First published in Machinery, January 2011