Electron Beam Electron Beam PIKA FINISH EBM
PF100S / PF300S

Electron-beam irradiation combines precision and surface strengthening
in one process.
In-house developed electron-beam Aperture enables maximum beam irradiation diameter of Φ60mm.

PF100S / PF300S

Main Features

Surface Modification

The PF100S / PF300S Electron Beam PIKA FINISH EBM is a machine that uses electron beam irradiation to modify the surfaces of items. The machine is intended for the modification of items of molding and medical equipment industries, as well as items such as acrylic resin, titanium, ceramic and other products. Since electron beam machining (EBM) only modifies a 5 μm layer on the surface of the workpiece, the machine can achieve extremely smooth surface without degrading the pre-EBM precision.
Additionally, minute chips, cracks, and scratches can be corrected, thereby improving water repellency and corrosion resistance as well as suppressing the incidence of mold deposits in resin molding. This is a new finishing technology applicable in a wide range of fields that can bring greater consistency in product quality.

Increased Mold Life

Outstanding Durability for Less Frequent Mold Maintenance
When electron beam is irradiated, it involves a machining process in which the work surface is rapidly heated and cooled to a normal temperature in a repeated cycle.
This modifies the structure of the work surface and boosts the corrosion resistance of the workpiece.
For the molds typically used in plastic molding, the mold release characteristics improve, allowing shorter mold cycle times. Additionally, the release surface is smoother in press molds, acting as an effective countermeasure against clogging.

Comparison of Rust after Exposure to the Open Air for 1 year


Without EBM : Rust is formed

With EBM : No rust
Air Vents Also Function as Intended by the Designer
The improved surface modification results in a low incidence of contaminant adherence, showing that the irradiation of the electron beam suppresses the incidence of air vent clogging.

Hand-polished surface (after injection molding)
Hand-polished surface
(after injection molding)
Surface irradiated with electron beam (after injection molding)
Surface irradiated with electron beam
(after injection molding)

Irradiation of Electron Beam of Core-pin Shapes in Connector Molds

Molded Connector
Molded Connector
Rear insert side
Rear insert side
Slide side
Slide side

Actual Examples The working life of a hot-forging die in a bevel gear shape where a hand-polished workpiece subjected to nitriding treatment is taken to be 1

Bevel gear


 
Before processing
(mold life = 1)
After processing
(mold life = increased to 3

[After processing]
We have an actual result of the combination of EBM and nitriding treatment extending the working life of the mold by a factor of at least 3. The image of the cross-section clearly shows that where the nitriding treatment is used after EBM, the outcome of finishing is that no layer is formed where "nitriding affects the microscopic crystal structure".

Effects of Electron Beam Irradiation and Cemented Carbide
Irradiation of electron beam results in a change to the micro-crystal structure in which the tungsten carbide structure separates into tungsten and carbide.

<Tool bit shape (Sodick original product)>
Before irradiation of electron beam

After irradiation of electron beam
+ hand-polishing

Workpiece material: Cemented carbide (WC); machining time: 5 min. (total); vacuum: 3.5 min.;
hand-polishing time: 1 min.; machine used: PF100S / PF300S

Applying electron beam to cemented carbide directs thermal energy onto the cobalt and tungsten in the surface and facilitates the hand-polishing.
It also suppresses problems such as undulation and contributes to improved quality.

Comparison of Cut Surfaces and Final Finished Surfaces

Before lapping
Streaking caused by cutting remains
After lapping

Product Specifications

PF100S PF300S
Work table With NC control With NC control
Machine tool dimensionsW x D x H(mm) 1040×1430×1800 1040×1817×1800
Work sizeW x D x H(mm) 100×100×100 300×300×100
Input voltage 3-phase, AC200V, 50A 3-phase, AC200V, 50A
Operational ambient temperature 20~30℃ 20~30℃
Operational ambient humidity 30~70% 30~70%
Power consumption 2.0kVA 2.0kVA
Air 0.4~0.6MPa 0.4~0.6MPa
Beam diameter 60 mm dia.
(workpiece flat surface, using standard beam conditions)
60 mm dia.
(workpiece flat surface, using standard beam conditions)

※Specifications can be changed for larger workpiece sizes.
Contact your Sodick sales representative for details.

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