Better accuracy for wire cut EDM

Edited by the Engineeringtalk editorial team Feb 25, 2002

Fanuc has extended the capacity, specification and performance of its new Robocut Alpha-1iB wire cut electrodischarge machine (EDM) launched at MACH 2002.

Fanuc has extended the capacity, specification and performance of its new Robocut Alpha-1iB wire cut electrodischarge machine (EDM) launched at MACH 2002.

With the fitment of Fanuc's latest FS 180is-WB control and MF generator, the new large capacity machine workpiece weight is 1t.

The machine is also able to provide higher accuracy than before at cutting rates up to 330mm2/min and carry out a wire feed inside 15s.

Now available from 600 Centre of Shepshed near Loughborough, the latest version of the top-selling Robocut can be specified with an optional workpiece capacity of 1000 x 730 x 400mm.

In standard capacity the machine will accept workpieces 820 x 730 x 300mm and has a cutting stroke of 550 x 370mm giving an additional 30mm of stroke to the x-axis.

And, in this standard specification, the new Fanuc requires 17% less floor space than before on the A-Series machine.

Productivity is enhanced with faster automatic wire feed which can be carried out when submerged on workpieces up to 300mm thick.

This now takes just 15s, some 20s faster than the previous generation machine.

The machine is now able to carry a 16kg bobbin of wire which enables unmanned running to be extended to 125h when using 0.2mm- diameter wire, 80h with 0.25mm wire and 55h with 0.3mm wire.

With the latest Fanuc FS 180is-WB five-axis control and 12.1in screen, a new operating panel, and i 'pulse' power supply, cutting rates up to 330mm2/min can be performed using 0.3mm coated wire and 300mm2/min with standard brass wire of 0.3mm diameter.

Non-electrolysis AC cutting, which is a feature of the new MF generator, prevents corrosion and, by reducing the heating effects on the recast layer of the material being processed, the surface does not soften around the cutting area.

Indeed, surface roughness better than 0.7um can be attained.

With the latest AI corner control, wire deflection is minimised and precise path control ensures maximum profile and corner accuracy.

When cutting into an edge of a workpiece, wire breakage problems caused by unstable dielectric supply or component surface oxidation are overcome with the latest machine enhancements.

The new AI cut-in function automatically adjusts cutting conditions and dielectric fluid pressure to ensure a smooth entry into the cut.

In addition, the adaptive control software detects any changes in workpiece thickness and automatically adjusts the process settings to maintain cutting efficiency and thus avoid wire breakage.

This feature can improve cutting speeds by up to 30% compared with conventional methods.

As an option, the Fanuc control can be specified with a five-axis capability giving additional C-axis component rotation.

This can be incorporated with a touch trigger probe to maintain a centre line dimension.

Travels for U and V axes are + 60mm and maximum taper angles for material up to 400mm thick is + 300 x 80mm with an option of + 450 x 40mm with automatic compensation.