EDM production times halved

A new Sodick AD3L CNC spark erosion machine featuring linear drives is halving EDM cycle times at CA Tooling Ltd, an East Kilbride-based injection mould tool specialist. Furthermore, the inclusion of an automatic toolchanger permits the company to run the machine unattended overnight and at weekends, negating the threat from competition based in low-cost economies. Founded in 1996 as part of CA Models (headquartered in Stirling), in the region of 90 per cent of turnover at CA Tooling is generated by contracts for the medical and telecommunications sectors. While CA Models focuses on the generation of prototypes via techniques such as stereolithograhy, selective laser sintering and vacuum casting, the establishment of sister company CA Tooling for the production of injection mould tools and mouldings enables the group to take designs from initial concept through to final production, ensuring continuity of product development. The group as a whole employs around 50 people. Having run its existing European-built spark erosion machine since the company's inception 12 years ago, CA Tooling has invested in the latest die sink Sodick EDM technology (Sodi-Tech EDM, 024 7651 1677). Installed at CA Tooling in spring 2008, the chosen machine, a AD3L die sinker, has been set to work, producing a wide variety of complex cores and cavities for injection mould tools. Typical materials tackled by the machine include P20 tool steel, stainless steel and aerospace-grade aluminium alloy. "A complex cavity would take around 48 hours on our old sparker," explains tooling manager Malcolm Cameron, "but with our new AD3L, similar jobs need no more than 24 hours, machining time. What's more, the automatic toolchanger gives us the ability to run unmanned, which, in the current economic climate, is a massive help when combatting competition from the Far East." Mr Cameron says he is also delighted with the improvement in quality witnessed since the arrival of the AD3L, stating that corner features are much more defined and that surface finish is also enhanced. "Its ability to achieve repeat tight tolerances is also better," he adds. "Some of the designs feature tolerances of ±0.01 mm on the plastic parts, which means they have to be even tighter on the tooling, as the plastic is prone to shrinkage. This is particularly the case with some of the medical components we produce, where the detail witnessed under a magnifying glass is nothing short of incredible." Image: Faster cycle times, unmanned machining, plus better surface finishes are benefits seen by CA Tooling with the AD3L EDM electrode wear solution GF AgieCharmilles (024 7653 866) has launched a new range of advanced die-sink machines into the market that provide users with the best of both worlds – high-speed cutting (fast stock removal rates) and zero electrode wear. The new range of IQ EDM machines, equipped with GF AgieCharmilles' new Hyperspark generator and ultra-fast and responsive controls represent: "the most significant and exciting development in spark erosion technology for over a decade". In the past (prior to the advent of IQ technology), there was always a compromise in EDM machining between achieving high-stock removal rates (and high electrode wear) or reduced electrode wear (and lower machining speeds). Depending on individual precision manufacturer's priorities, generator settings could be altered to achieve an 'acceptable balance' between the two. This is no longer the case with the new technology. The IQ machines' true potential and ultra-productive performance is realised when using graphite electrodes, says GF AgieCharmilles. First published in Machinery July 2009