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moldmakingtechnology.com 97 to 9 EDM Pages 91 to 98 Sinker EDM Enables Zero Electrode Wear Sodick's AD35L sinker EDM features no-flush technology designed for increased mach- ining speed, higher manufac- turing efficiency, reduced cost and shortened delivery time. The technology enables EDM machining of steel materials with virtually zero wear on the graphite or copper electrodes, the company says. Rigid linear- motor drives enable high-speed, high-precision EDM operations while also reducing maintenance and prolonging accuracy. The machine also features heavily ribbed Meehanite castings for the bed, table and column construc- tion, further promoting accuracy. It offers X-, Y- and Z-axis travels measuring 13.78" x 9.84" x 10.63" (350 x 250 x 270 mm) and can accommodate workpieces weighing as much as 1,212 lbs (550 kg). Sodick Inc. / 847-310-9000 / sodick.com Wire EDM Series Suited for Mold and Die Components The AgieCharmilles CUT 200/300 MoldTech series of wire EDMs from GF Machining Solutions is equipped with features and capabilities designed for accurate and efficient machining of highly complex parts with variable surface heights or taper cuts. Such components include those for plastic injection molds and aluminum extrusion dies, and for the aerospace and medical industries. The specialized MoldTech package is available on four of the company's high- speed wire EDM models built for machining larger, complex workpieces: the CUT 200 mS, CUT 200 Sp, CUT 300 mS and CUT 300 Sp. At its heart is the Taper-Expert smart module for cutting precise large taper angles with high-quality surface finishes. According to the company, this module allows the use of large radius wire guides and soft brass wire, and it compensates in real time for the pivoting point drift in the Z direction when the angle changes. The results are surface finishes of (Ra) 0.2 micron and better angle cuts ranging to 30 degrees. The dedicated onboard AgieCharmilles AC CUT human-machine interface is said to reduce setup time and improve productivity. GF Machining Solutions / 847-913-5300 / gfms.com/us The POCO EDM Reporter is Back! POCO's EDM Reporter is your resource for useful tips on improving productivity in EDM and Machining operations, as well as features spotlighting POCO customers and future activities. Register for upcoming issues at www.POCOEDMReporter.com POCO® is a registered trademark of Poco Graphite, Inc. Strategic Partnerships develop for a variety of reasons, but all the members benef t from the joining of resources to reach a common goal. Recently, what started as one man's problem quickly evolved into a problem solving event for three individuals. The problem job involved an accelerator pedal bracket for a car that required numerous deep slots for strengthening ribs in the f nal plastic. The customer specif ed ampcoloy as the core material and the production schedule was tight. other high copper burn – the EDM e Sink Manager n to determine uired to fi nish d up to four r methods to ajority of work Chris Double, John Shore and Jerry Mercer (left to right) review settings and discuss performance of EDM-C200. Company: pt mold, craft, mI p , ouble, Die Dm manager , maChInE: shi EX-22 ElECtroDE: Dm-C200™ applICatIon: oy Cores motive y Essential for Surviving in Tough Times nge s uring or the ging ry. This is ing costs by taking upplier. As die industry customers rate goals. rformance esses to materials d lead-time Graphite and the desired c partner visits to address These benefts s become better with electrode uce operational l Shop foor applications support l Performance / cost ratio analysis l technical publications l Productivity improvement solutions l training seminars POCO BENEFITS SFM FEEDRATE graph te s the POCO EDM Techn ca Manua . n th s manua s a chapter devoted to machining graphite and contains guidelines and recommendations on SFM ranges for HSS, Tungsten Carbide and Diamond cutters. Many shops cut outside these ranges; however because of tooling or spindle limitations there are many that do not have the ability to run at the feedrate thought to be required to generate enough heat to machine graphite. This is not a problem as some may think. Graphite is not cut by the same mechanisms as steel, aluminum and other metals. In this case, metal chips are formed by a ductile deformation process. This occurs when cutting at the proper feed and speed rates to create a tiny spot of heat softened metal just in front of the tool's cutting edge. This tiny spot makes the metal easier to cut and reduces the power required for the cut. Cutting metal too slow does not generate the proper cutting conditions to create the heat softened zone for metal removal. On the other hand, cutting metal with higher feed and speed rates than required will generate too much heat and afects the cutting tool. Both of these situations will reduce the life of the cutter. So what happens when cutting graphite? Does it soften if we get enough energy into the cut? Not really. Graphite does have certain conditions under which it softens, but these conditions cannot be met under normal atmospheric pressure or oxygen content present in the typical machine shop. The temperature required to "soften" graphite is over 3000° C. At this temperature, the cutting edge of the tool would soften and become inefective in the cut. Also at this temperature, the graphite would react with the oxygen and oxidize when it came into contact with the shop's air. For this reason, common machining practices cannot develop the temperature required to soften the graphite. Instead, graphite is removed by a fracturing process. With this, the surface of the material is broken into tiny pieces with some l Shop foor applications support l Performance / cost ratio analysis l Technical publications l Productivity improvement solutions l Training seminars POCO BENEFITS www.poco.com