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Case Study / Topic 36 MoldMaking Technology —— MARCH 2018 Case Study / Automation micro-welding for repairs and tooling alterations while keep- ing pace with EDM production. These results led Summit Tooling to add a second EDAF2 EDM machine with a fine-hole EDM drilling option to the cell in 2012 for the purpose of producing high-tolerance, small-hole tooling features. The fine-hole machining option makes it possible for the EDAF2 to change 0.0039-inch-diam- eter by 12-inch-long pipe electrodes with its ATC. Special automatic dressing routines also are capable of discharge- dressing electrodes as small as 0.0035 inch in diameter, which can produce finished hole sizes of 0.004 inch in diameter using the EDAF2 fine-hole option. "We have two customers that use nano-injection mold- ing for surgical applications. You need a microscope to see the parts. Some are 0.125 inch in length and 0.003 inch in diameter. The fine-hole option allows us to produce holes smaller than 0.012 inch, which is a typical limit using tradi- tional hole-popper EDM machines. The difference with the EDAF2 is that the holes it produces are always within size and straightness specifications," Martin says. Summit Tooling also has increased productivity 30 to 40 percent by replacing older commodity machines that required operators' continual attention. Machinists can now manage several manufacturing cells simultaneously and take on new roles in the company's growing plastic-injection mold- ing operation. Operators set up automated cells and then run laser welders and other machines during their shift while the cells run unattended overnight and on weekends, providing improved delivery times. Completely Automated Cells Change Processes Martin made a bigger step toward full automation in 2011, when he hired Makino to integrate an EDM cell that includes a Makino F3 vertical graphite machining center with a pressur- ized system to vacuum carbon dust for high-speed electrode milling. The cell also has two EDAF2 sinker EDM machines for the production of slides, core pins, cores, cavity details and cavity-forming shapes. A larger System 3R Workmaster system feeds tooling and workpieces to each of the machines. "Adding the cell changed how we do things enormously," Martin says. "It takes a change in mindset to get used to running machines unattended 24/7. A change in mindset was especially necessary considering that now we can set up the machines, leave on Friday and then come back on Monday morning, real- izing that we just ran 72 hours' worth of work through three machines, and none of our employees were here." The company has since added two more automated cells. One is a milling cell with a Makino F5 vertical machining center that Summit Tooling installed in 2013 and integrated with the two S33 vertical machining centers that the company purchased in 2008 using a second System 3R Workmaster. This cell replaced nine commodity vertical mills. The second is an EDM cell that Summit Tooling installed in 2014–2015 combining two Makino U32j and one U53Tj wire EDM machines that are loaded and unloaded by a third System 3R Workmaster system. The U32j and U53Tj wire EDM machines feature Makino's Hyper-i control, which uses touch-screen controls with pinch, swipe and spread functions similar to functions in modern smartphones. According to Summit Tooling, operators have been able to adapt to the interface easily and implement it easily. The on-board digital manuals, help functions and e-learning training system have given operators practical sup- port tools to boost machine productivity. The Hyper-i control also includes HyperCut technology that Makino claims can produce a 3-micron-Ra (16-microinch-Ra) surface finish and 1-micron (0.00004-inch) straightness in three machining passes, while simultaneously reducing cycle time. After installing the first U32j, Summit Tooling tested it against one of its older commodity EDM machines by run- ning a job that previously took 12 minutes. A Summit Tooling operator produced the same part, running the same program used on the older machines, in less than five minutes. Wire consumption is down by 14 percent. "Our previous EDM machines were five to seven years old. We want to stay ahead of the technology curve, so we invested