EDM Technologies for Preventing Machining Errors and Attaining Higher Precision

GF Machining Solutions is highlighting the Intelligent Spark Protection System (ISPS) and iWire with Spark Track technology, which give shops the ability to fully optimize their entire moldmaking process with electrical discharge machining (EDM). These technologies are designed to significantly improve machining accuracy, reduce downtime and provide overall increased productivity.

It is said one of the biggest challenges in EDM moldmaking is irregular-shaped parts (not flat top and bottom) which can cause uncontrolled sparking, wire breakage, inconsistent surface finish and reduced accuracy in workpieces. The ISPS intuitive engineering counters that by evaluating the exact position of each spark discharge from wire to machined part, detecting irregular sparks and adjusting parameters instantly to prevent machining error. This helps eliminates wire breakage, enhances surface finish and ensures consistent quality across mold components.

When using wire-EDM for moldmaking applications, manufacturers need to maintain accuracy while reducing wire consumption. The iWire with Spark Track technology automatically detects and adapts wire speed to changing erosion-height conditions during the wire-EDM process. Wire-spool speed is reduced or increased automatically, according to workpiece height changes during normal or unattended operations. This option reduces wire consumable cost, in some cases up to 20%, depending on thickness changes. In addition, iWire working in tandem with ISPS optimizes the machining experience.

By adding ISPS and iWire into EDM moldmaking processes, manufacturers can achieve higher precision, less downtime, enhanced productivity and reduced operating cost.