At the heart of the innovation is GF Machining Solutions’ generator technology - specifically its ISPS (Intelligent Spark Protection System) module - which identifies the intensity and location of sparks along the wire and, when necessary and required, adjusts current and voltage rates to prevent any concentration of wear.

Spark Track provides real-time spark distribution information to manufacturers, enabling them to push their EDM machines to the limit.

Says Martin Spencer, managing director at GF Machining Solutions UK: “The ISPS module eliminates wire breakage regardless of machining conditions and, as such, makes wire EDM processes more reliable and secure.”

Spark Track solves problems such as wire oscillation, which can occur when machining different heights and tapered surfaces and, in turn, lead to wire breaks and damaged workpieces.

Says Spencer: “Superior wire-cutting performance is achieved when discharge distribution along the wire is as uniform as possible. Spark Track enables this to occur.”

ISPS and Spark Track, working in combination, not only prevent wire breaks, they also (as a consequence) eliminate time-intensive resets and reduce the amount of time an operator has to devote to a given job.