Both the Power 400 grinder and the two-in-one Power Diamond 400 grinding-eroding machine for the production of carbide as well as PCD tooling have extended traverses to enable tools up to 380 mm long to be processed, an increase of more than 35%, compared to the previous limit of 280 mm.
Tools of 3 to 315 mm diameter can be accommodated on machines which have X, Y and Z axes travels of 650, 350 and 720 mm, respectively.
In addition to this change, both have been completely redesigned (in line with the Walter Vision models) and feature, for example, a very rigid cast iron bed – up to 70% more rigid - to ensure improved damping characteristics, which in turn facilitate greater precision and higher surface quality.
Furthermore, as standard there is a 26 kW, 10,500 rpm spindle, and an accurate, low maintenance torque motor is available for the machines’ C-axis, which is driven by worm drive on standard versions.
Walter engineers have also replicated the Vision machines’ pneumatically-driven steady-rests and tailstocks – devices that are less prone to leaks, require less maintenance and are much cleaner. They also absorb less heat than components that use hydraulic oil, thus ensuring higher precision.
In addition to having a grinding wheel/electrode changer (four-station as standard; eight-station optional) for increased automation and unmanned operation, both machines can utilise a range of robot loading solutions - the Top Loader for up to 500 tools, a Robot Loader for up to 7,500 tools or a Robot Loader 25 which has a capacity for tools weighing 25 kg including grippers.
The new machines incorporate the Helitronic Tool Studio grinding and eroding software with integrated wizard technology for fast tool production simulation, parameter changes and machine operation. The latest version (3) of the software includes an erosion function option for the fast and easy programming of ‘what you see you can grind and erode’.
Like all of Walter’s two-in-one grinding-eroding machines, the new Helitronic Power Diamond 400 uses Fine Pulse Technology, a Walter innovation that sets new standards in terms of PCD tool surface and cutting edge quality, as well as process reliability.
Fine Pulse Technology is the result of progressive improvements to the machines’ generator as well as the erosion software.
Marked differences to PCD tools of 10 microns grain type that have been eroded by other machines can be seen with the naked eye - the surface finish is like that of a polished (ground) tool – and even coarse-grained PCD types can be fine-finished with perfect surface qualities.
With such super-fine finishes achievable with Fine Pulse Technology, PCD tool providers can achieve superb levels of tool surface quality and cutting edge within similar processing times as before. Also, subsequent steps in production can even be eliminated because no re-sharpening or polishing is required.