Advanced technologies for sinker and other EDMs

To improve performance, reduce cycle times and enhance machine operation, Makino Inc. has released Hyper technologies for its full line of wire, sinker and holemaking EDMs. By standardizing these innovations, the machine tool builder hopes to produce more versatile machine operators who can learn, adapt and alternate between EDM platforms.

Makino’s Hyper-i control, as well as HyperCut, was originally introduced for its U-Series wire EDMs 2 years ago. “We’ve recently expanded these capabilities to empower the EDM operators with technology they can access immediately on the shop floor,” said Brian Pfluger, EDM product line manager at Makino. “Today, a wire EDM operator can switch to a sinker EDM with minimal effort and vice versa.”

In the case of Makino’s sinker EDMs, Hyper-i represents a machine control Pfluger likens to a smartphone or a tablet. “Everything we love about our personal devices has been incorporated into Hyper-i,” he said. “It features a graphically orientated interface, a larger screen and easier programming functions. Everything is more accessible and easier to manage than previous machine controls.”

Makino’s Hyper technologies are available for all EDM equipment, giving operators more shop floor versatility thanks to a new control and a cutting process that reduces roughing speeds for sinker EDMing up to 30 percent.

Additionally, the HyperCut technology has been added to reduce cycle times. For Wire EDM, Hypercut produces a fine surface finish with less machine passes with lower wire consumption. A surface quality of 16 µin. Ra (3µm Rz can be achieved with three-pass machining (one rough, two skims) using brass wire. For a sinker EDM, HyperCut enables the machine to reduce roughing times up to 30 percent. This is possible thanks to new generator hardware that allows the machine to more efficiently apply power to reduce machining times via the control, according to Pfluger. “Now incorporated into our sinker machines, the addition of HyperCut offers faster speeds, maintains minimal wear and achieves better surface finishes,” he said.

Unique to sinker EDMing, HyperCut technology can be utilized with any electrode and does not require additional changes to electrode reduction to significantly reduce cycle time. The technology is able to apply more power to the electrode to improve machining speeds while not changing the overburn amount and resulting part size and surface quality.

Another growing area of development is the ability to immediately access information. Makino has embedded features in the control that empower operators with information when and where they need it.

“When you’re setting up a part using a pickup cycle and you’re unsure about a particular function, the machine manual is embedded in the control,” Pfluger said. “You can just jump to the appropriate section to get the information from the digital manual. If that’s not helpful enough, they can link to an onboard video directly on the screen as an added resource.”

Suitable for wire and sinker machines, the E-Tech Doctor can be accessed when a machine is cutting too slowly and an operator needs assistance. The E-Tech Doctor captures the knowledge of a seasoned application engineer directly on the machine, according to Pfluger.

“The operator can select a function, answer a couple of questions regarding the cut and the machine will automatically change the power settings,” Pfluger said. “It’s an opportunity to assist new machine operators with minimal training and let them be more productive.”

For more information about Makino Inc., Mason, Ohio, call (513) 573-7200 or visit www.makino.com.