GF MACHINING SOLUTIONS’ new iWire function automatically identifies and adapts wire speed to changing erosion height conditions during the wire EDM process. As the first of its kind for electrical discharge machining (EDM), this capability eliminates wire breakage while reducing overall wire consumption per job, in some instances by as much as 29%.
The iWire function is featured on the new CUT P Pro Series wire EDMs, and works in tandem with GFMS’ Intelligent Spark Protection System (ISPS), both of which are part of the company’s Uniqua control.
What started with GF Machining Solutions Spark Track technology four years ago has advanced to the ISPS and now iWire technologies. Building on its amassed technological knowledge from decades of experience in EDM, the company can not only recognize exactly where the sparks of a wire EDM are happening during the process, it can also measure and identify the position of each spark along the length of an EDM’s wire.
Knowing the exact location of a spark allows iWire to adapt the wire spool speed accordingly. Such capability reduces the chances of wire breakage during unattended operations when EDMing parts with steps and other features that vary the erosion height – the length of the actual surface areas where the wire is eroding/cutting.
Both ISPS and iWire help prevent wire breakage in any conditions while also lowering wire usage to reduce consumables costs and increase EDM productivity. In testing, iWire working with ISPS prevented wire breakage on a part with numerous features with varying erosion heights. The cut started at a standard spool speed, then when the cutting height lessened, the speed slowed. As a result, wire savings equated to about 480m or 0.2kg, and overall process time savings amounted to 28 minutes for a 30% overall reduction.
In another customer test, ISPS and iWire reduced wire break areas from nine to zero. The customer reduced wire consumption by 29% and eliminated machine stoppages due to wire breakage.
Learn more at www.gfms.com