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Astoundingly high-speed machining is achieved |
Hybrid Wire EDM
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Many Wire EDM users have expressed the need for "faster cutting speeds, higher accuracy and improved quality". Traditionally, Wire EDM cutting speeds cannot exceed 500mm 2/min, a feature which all EDM manufacturers are striving to improve. With this in mind, Sodick set out to develop a way to dramatically improve wire cutting speed, examining unconventional methods in the process.
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 Outline
The introduction of the "Hybrid Wire EDM" reveals an innovative new product that combines the "ultra-high precision machining" of Wire EDM with the "high-speed machining" of waterjet cutting. In order to facilitate the development of this machine a partnership has been made with the world's largest waterjet manufacturer, "Flow International Corporation", whose corporate office is in Seattle, USA.
Sodick has long been involved in manufacturing precision parts. With this revolutionary new Wire EDM, Sodick is confident that in the future electrical machining will increase in demand to satisfy both high-speed and high-precision production, and help re-shape manufacturing processes.
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| 1) |
The World’s First! |
| Wire EDM and Waterjet are combined into a single "Hybrid Wire EDM". |
| 2) |
Rough cutting speed (1st cut) by waterjet is dramatically 20 times faster than wire-cutting. |
| 3) |
Initial hole cutting and disposal of core are performed ready for automated operation. |
| 4) |
This "Hybrid Wire EDM" can be applied to any 3 different requirements, such as waterjet cutting only, wire cutting only or combined machining with waterjet and wire-cutting. |
| 5) |
The combined Hybrid machine can be installed at small sites. |
| 6) |
Environmentally-safe graphite cutting does not diffuse particles. |
Wire-cut portion
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Waterjet portion
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| 1) |
The World’s First!
Wire EDM and Waterjet are combined into a single "Hybrid Wire EDM" . |
Combining 2 separate machine tools is extremely difficult.
However, Sodick facilitated the task of successfully completing the Hybrid Wire EDM by using the linear motor drive technology that it had already developed. |
| 2) |
Rough cutting speed (1st cut) by waterjet is dramatically 20 times faster than wire-cutting. |
| An abrasive waterjet, ie, one which uses abrasives in the water fluid, is most commonly used. The "Hybrid Wire EDM" also uses abrasives. However, the unique feature for the "Hybrid Wire EDM" is its "ultra high speed cutting". Graphite material, which is traditionally cut by Wire EDM, can be cut up to 20 times faster than Wire EDM for the 1st rough cut which is 10,000mm2/min for 50mm thick). The standard material for mold and die is D2(52 HRC) which can be cut at 1,400mm 2/min (94mm/min for 15mm thick) |
| 3) |
Initial hole cutting and disposal of core for press mold are performed ready for automated operation. |
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The initial hole cutting, which until now was impossible on Wire EDM and used to be carried out on a separate machine, can be performed on the "Hybrid Wire EDM". Furthermore, the core, produced during transfer-press manufacturing, drops naturally. This also helps achieve automated operation. In short, once a hardened steel plate is set on a "Hybrid Wire EDM", all the machining from initial hole cutting, core handling and finishing is performed automatically without operator intervention.
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| 4) |
Depending on the requirements, either waterjet cutting, wire cutting or combined cutting can be selected. |
- Ultra-high-speed cutting by waterjet only, even for insulated materials
- Ultra-high-precision and thick material can be cut by a Wire EDM
- Ultra-high-speed cutting by waterjet and finished by a Wire EDM method enable various machining for all kinds of purposes.
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| 5) |
Small Floor Space for a Hybrid Wire EDM |
| Traditionally, two separate machines used to be required for waterjet cutting and wire cutting which took up valuable floor space. The Hybrid Wire EDM eliminates this problem with just one small footprint. |
| 6) |
Environmentally-friendly machine, since graphite cutting does not become air- born. |
| Both waterjet cutting and wire cutting use water fluid in the Hybrid Wire EDM, thus ensuring graphite chips do not become airborne. |
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Wire portion
| Travel(X, Y, Z axis) |
550 x 350 x 250 mm |
| U, V axis |
550 x 350 mm |
| Taper cutting (for 150 mm T) |
±30° |
| Wire electrode diameter |
Φ0.15 ~ Φ0.3 mm |
| Max wire spool |
20 kg |
| Max wire feed speed |
420 mm/sec |
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Waterjet
| Travel(X, Y, Z axis) |
550 x 350 x 250 mm |
| High pressure flushing power |
380 MPa |
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Hybrid Wire
| Max workpiece dimensions |
750 x 550 x 200*1 mm |
| Max. workpiece weight |
700 kg |
| Distance between floor to table top |
1,050 mm |
| Machine body dimensions |
3,885 x 4,745 x 2,500 mm |
Machine floor space
(excluding maintenance space) |
3,900 x 5,300 mm |
| Machining fluid |
Ionized water |
| Air supply |
450l / min |
| Fluid filtering method |
Replaceable paper filter |
| Fluid cooling method |
Cooling unit |
| Service tank capacity |
2,200 L |
*1 When the Hybrid machining, Waterjet machining: 40mm
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Rough cutting(waterjet)