Makino EDNC 21 – Sinker EDM
With its twin head machine configuration, the EDNC21 Ram EDM machine provides very unique and highly productive capabilities. The double-headed machine design enables independent programming and execution of different part features at the same time, which can significantly impact throughput for large die-and-mold tooling. Even with its large size, the EDNC21 machine is capable of achieving high positional and feature accuracy with fine surface finishes. The precise and rigid construction utilizes a stationary worktable design that positions the dual gantry-style heads over the work piece while supporting part weights up to 22,000 lbs. (10,000kg). Using a programmable rise-and-fall front door system, it provides excellent work tank access.
The EDNC21 machine has a work tank size of 122” x 71” (3,100mm x 1,800mm) and provides X/Y/Z strokes of 78.7” x 59.1” x 31.5” (2,000mm x 1,500mm x 800mm). The machine features dual independent ATC (automatic tool changer) systems, dual independent controllers and dual independent power supplies to facilitate multi-process machining. The ATC system can be configured with a 10- or 32-tool magazine to provide prolonged unattended machine operation. The EDNC21 EDM machine can also be configured with the HS-Rib high-speed Z-axis that achieves jump motions up to 20m/min. The HS-Rib Z-axis maintains high-speed jump motions with precision depth control using integrated core-cooled ballscrew construction. The efficiency benefits of the HS-Rib system can reduce cycle time by up to 60 percent, which enables the large EDNC21 machine to attain similar capability and performance found on much smaller machines.
The EDNC21 machine makes use of dual Hyper-i control systems, which provide the ultimate in user-friendly operation and flexibility. Operators of all skill levels will appreciate the graphical nature and intuitive streamlined flow of the Hyper-i control system and will make effective use of the system’s time–saving, on-board digital manuals and advanced E-Tech Doctor help functions. The large 24” class hi-definition touch screen offers an easy, inviting approach to machine functionality. However, the real advantage of the Hyper-i control is its ability to intelligently apply the power of Makino’s advanced technologies, such as HyperCut and SuperSpark™ IV, in delivering the most efficient and productive machine operation.
• HyperCut: This special generator setting provides improvement to machining speeds without increasing electrode wear or required electrode reduction amount. HyperCut can be used on part details up to 30 amps, and improves machining speeds by up to 30 percent without affecting surface quality.
• SuperSpark™ IV: This family of technologies utilizes dynamic power supply adjustments and jump motion control during the machining process. It enhances automation and unattended operation capabilities by eliminating the need for external flush lines and increases the control’s ability to maintain higher cutting speeds regardless of the application or operator’s experience level. Reduction in rough machining cycle times can be achieved when using SuperSpark™ technology regardless of the shape, size or depth of cavity.
• ArcFree: This set of safety-focused settings virtually eliminates the possibility of the machine developing destructive DC arcs during the course of a burn. ArcFree technology, coupled with Makino’s extremely fast servo control response time, enables safe, unattended burning, even when the current applied to an electrode exceeds its maximum current density. While arc prevention has been a part of all modern sinker EDMs, ArcFree technology is the next advancement in intelligent adaptive controls for prevention of DC arcs.
• Flower pattern: Special conditions were developed to obtain a uniform Ra value surface finish with a large RSm value to improve the performance of mold release for plastic injection tools. The more open structure of the surface finish improves plastic part mold release and tool life while reducing the interval for mold cleaning maintenance.
• HQSF™ (High-Quality Surface Finish): This optional configuration dramatically improves the produced surface finish of tool steels using copper or graphite electrodes. The technology was specifically designed to eliminate post-machine polishing and produce superior metallurgical results that extend tool life. Makino’s HQSF process uses a special µSC powder additive that is mixed in the dielectric oil that enhances the stability and even disbursement of the machining spark energy. HQSF can also provide cycle time reductions when not machining to ultra-fine surface finishes.
• EDcam™ software: Makino has developed an off-line programming system for Ram EDM that makes use of the electrode and work piece CAD model information. The system eliminates the requirement of having to create paper process sheets for manual data entry of the programs on the machine control, which invite critical human errors. By intelligently utilizing available electronic data, the EDcam software brings the Ram EDM process into the 21st century and provides a means of program simulation and verification without the need for time-consuming, on-machine, dry-run operations.
• Remote machine monitoring: As part of efficient unattended machine operation, operators and supervisors alike may wish to monitor the machining progress while away from the machine. Makino offers two software options that provide a means of process updates. The EDM mail option enables the machine to generate e-mail text-based messages on any alarm/stop status or by timed intervals. The EDM viewer option provides direct viewing of the machine control interface on a remote PC.
