EDM and high-speed milling are key processes in the manufacture of molds that compete with each other and complement each other. In the past decade, with the continuous development of superhard tools, drive technology, machine tools and control technology, high-speed milling has replaced EDM in some occasions. The high-speed milling process has unparalleled high efficiency when processing free-form surfaces and large-volume cavities. Due to high processing precision and good surface quality, the subsequent supplementary processing can be eliminated, which greatly simplifies the production process. However, EDM processes, such as machining deeper, narrower or have a small fillet radius of the cavity and machining complex geometries, and when machining mold parts with hardness exceeding 60 HRC, Better technical and economic advantages than high speed milling.
It can be seen that through the combination of high-speed milling and EDM, the advantages are complemented, that is, the EDM machine and the high-speed milling machine are connected into one unit or one system through industrial robots and workpiece storage. Processing, thereby improving production efficiency, reducing the cost per piece, improving machining accuracy and shortening production process time and delivery time, thereby enhancing the competitiveness of enterprises.
In the past 5 to 6 years, EDM machines have been produced in Europe, and high-speed milling machines have been manufactured at the same time, such as OPS-Ingersoll in Germany, GF Agie Charmilles in Switzerland, and Germany. Companies such as Exeron have introduced automated integrated processing equipment such as machining units or mold centers that integrate EDM and high-speed milling.
GF AgieCharmilles exhibits its expertise in EDM and high-speed milling in the field of mold making, and displays an integrated milling and power application in its Schorndorf application and service center. Spark-processed linear machining unit for the manufacture of inserts for injection molded cores. The high-efficiency machining centers (Mikron UCP 600 Vario) and EDM machines (Form 2000) operate the handling of the electrodes and the workpiece pallets by means of a robot (Workmaster Linear-System 3R). The unit is modular and can be expanded as needed. According to reports, the use of this equipment can reduce manufacturing costs by 46%.
After accepting the processing task as an order, the processing unit can start from CAD/CAM, from programming, machine control, workpiece pallet clamping, electrode and milling cutter selection, machine tool start-up and finished workpieces. The access to the workpieces on the lower and the framed repositories can be automated, and the worker only needs to load the workpiece pallets into the framed storage of the processing unit at the loading and unloading station. Through the automation solution, the machine tools of two different machining methods are integrated to realize the comprehensive and efficient machining of the workpiece. Customers can take their processing tasks to the application center and use GF AgieCharmilles' proprietary technology to help find the right solution.
Ruhla Mould Manufacturing GmbH is a small company that manufactures injection molds, dies and bending dies, with 45 employees. In the past few years, due to the development and development of the company's business, the EDM capability of the existing two machine tools can only reach 5,000 hours a year, but actually takes 8,000 hours. The purchased electrodes and the external EDM process often fail to meet the quality requirements of the factory. At the time, Ruhla's leadership saw an automated solution for EDM in the application and service center of GF AgieCharmilles in Schorndorf, and decided to work with GF AgieCharmilles. In early 2008, a fully automated, integrated EDM and high-speed milling of graphite electrodes was installed in the company. At the time, this equipment was the first in Europe to invest in a highly modern processing unit. The technology has greatly enhanced the company's competitiveness.
This set of processing units is mainly composed of the following equipment:
â—‡ Two EDM machines (Agietron Impact 2 and AT Hyperspark 2 HS);
高速 High-speed machining center (Mikron HSM 300 Graphite Master);
â—‡ Coordinate measuring machine (Veze of Zeiss);
â—‡ Joint Industrial Robot (Handling Tech);
识别 Identification system (Flashender of Zwicker Systems);
â—‡ System Management Software (Zwicker Systems, Inc.);
装 Loading and unloading station and loading station (for processing unit).
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