New Sodick Sinking EDM
AL series: AL40G / AL60G / AL80G
Hi-Precision Flat Linear Die-Sinker EDM
- AL40G: XYZ travel = 400 × 300 × 270 mm
max workpiece weight = 550 kg - AL60G: XYZ travel = 600 × 420 × 370 mm
max workpiece weight = 1500 kg - AL80G: XYZ travel = 850 × 520 × 420 mm
max workpiece weight = 3000 kg
Gap Correction Rate > 1000 / sec
Z axis feed = 600 mm/sec
Accelleration = 2.0G
No-Flush Machining ready
More than 60 000 Sodick Flat Linear Motor EDM in operation throughout the World
Manufacturing of machine-tools
with flat linear motors since 1998
The first and the only manufacturer
of die-sinking EDMs
with linear motors
NANO-WEAR: less electrodes – more job
and ceramic work table
- Programmable 3-sided rise / fall work tank
- Wide open space allows easy workpiece set up
New Sodick Sinking EDM
ALC Series Feature
- X Y Z axis FLAT Linear Motors
As all Sodick EDMs, the “AL series” machines are equipped with the in-house developed and manufactured rigid flat (planer) type core linear motors (since 1998). High-power and high torque motors demonstrates high-speed and super high response machining.
Z axis Twin Linear
Z axis speed up to 600 mm/sec with acceleration of up to 2G - Linear motor cooling unit
- “M4-LINK” – new Sodick Motion Control (SMC)
New proprietary SMC “M4-LINK” (developed by Sodick America Corporation, San Jose, California) replaced the more than successful K-SMC system.
Response time is shortened to 0.4~1.0 μs. The system now precisely corrects the position of an electrode in the gap up to 1000 times per sec. - X Y Z axis absolute linear scales 10 nano (0,01 micron) Heidenhain.
- Ceramic Work-Zone Improvement in geometric accuracy by 3-4 times in comparison with metal-plastic working areas of non-Sodick EDMs.
Sodick ceramics thermal expansion is merely 4.5×10-6/°С.
Complete galvanic (electric) isolation of the Work-zone.
The ceramic quill developed by Sodick featuring lightweight, high rigidity and no thermal deformation is driven on both sides by linear motors in a symmetrical manner (Sodick patent) and enables extremely accurate and smooth motion without causing deviation or distortion of the slideways.
- Hand scraped contacting bearing surfaces of meehanite cast iron parts
- All bearing construction parts of low thermal expansion meehanite cast iron (11×10-6/°С)
- Symmetrical machine base design
- THK SSR guideways (caged ball technology) designed for use primarily in precision measuring machines. The guideways can withstand movements 100 times more than the distance from the Earth to the Moon and back.
new FUNCTioNALITY AND PRECISION
Newly Developed “SP Power Supply” Improves Machining Performance
The communication and throughput speed has improved in the newly developed “SP Power Supply” for the die-sinker EDM, which increased the motor control response speed by more than double. The adoption of the new “TMM4” and “BSN4” circuit improves the quality and speed of the overall electrical discharge machining range.
| Copper-Steel | Enhanced motor control response and the development of the BSN4 finishing circuit increases the machining speed |
Copper Tungsten – WC | The new TMM4 circuit increases the machining speed for copper-tungsten/ carbide |
Copper Graphite – WC | Improved control resolution of the SGF function |
Copper – Aluminum | SGF control adopted for aluminum to increase the machining speed |
- Smallest Corner R Machining
- Stainless St – Cu, depth 0.3 mm
- Surface Finish – Ra 0.12 µm (Rz 0.5 µm)
- Bottom Corner R – 4 µm
- Multi-hole Machining by Intricate Electrode
- Stainless steel – Cu electrode, depth 5 mm
- Surface Finish – Ra 0.072 µm (Rz 0.41 µm)
- Electrode Wear – finishing 0.002 mm (bottom)
Machining WC workpiece CuW electrodes using “TPC4”. Total Machining Time reduced by 28% compared to a conventional
The linear motor drive generates an ultra high-speed (up to 600 mm/sec) pumping effect efficiently removing chips, gas and carbon which exist between the electrode and the work piece. Therefore, machining can be performed without the need for flushing.
Ball-Screw EDM
flushing (non-Sodick)
Uneven flow of flushing results in not only residual chips, gas, and tar, but also uneven concentration of dielectric fluid
Sodick Linear EDM
no flushing
The rapid upward motion generates negative pressure between the electrode and the workpiece surface, where dielectric fluid rushes in together with chips, gas and tar.
The residual chips, gas, and tar cause secondary discharge, leading to unstable gap conditions, discharge spots or excessive discharge.
The chips, gas and tar existing between the electrode and the workpiece are efficiently ejected together with the dielectric fluid.
Long Pin Gate Machining
Mirror and Matte Finishing
No Flush EDM process using the pump effect of fast moving electrode (600 mm/min)
Workpiece Steel (HR50-53) – Cu Electrodes
Machining Depth = 30mm (tapered 1°/side)
Pilot Hole – ∅ 0.80 × 27 mm + ∅ 0.30 × 3 mm
Outlet Diameters = ∅ 0.50 mm
No. of Electrodes: Roughing (mirror and matte finish): 1 Semi-Finishing
(Mirror and matte finish): 1 Finishing
(Mirror finish): 1 (Total 3 / hole) (Matte finish): 1 (Total 3 / hole)
Electrode undersize = 0.05 mm/side
Surface Finish (mirror) = Ra 0.08 µm
Machining Time mirror = 2h 25 min
Surface Finish (matte) = Ra 0.15 µm
Machining Time (matte) = 1h39 min
BSN4 Machining Time improved by 21%.
High-speed finishing with uniform surface quality
Copper electrode – steel workpiece (SKD-11)
Electrode size – discharge area approx 10 mm dia
Machining depth = 1 mm // undersize = 0.20 mm/side
Surface finish (roughness) = Ra 0.11 µm (Rz 1.0 µm)
All cutting conditions generated by LN Professional (Artificial Intellect)
- Dielectric fluid cooling unit
- SVC circuit
- “SGF4” Nano-Wear Discharge Unit
- TMM4
- BSN4 finishing circuit
- SP controller
- 19″ TFT colour screen
- Intelligent Q³vic EDM
- LN Professional AI software for optimum condition search
- No-Flush Machining
- Remote controller
- 3-side rise and fall work tank
- Clamping chuck
- LAN interface
- USB port
- Totalising hour metre
- Work light
- C-axis SEC10 (20 rpm)
- ATC Unit (4, 12, 16, 32-station)
- SCF72P High-precision rotary head (2000 rpm)
- 40A Booster
- Table Down 50 mm (Factory option)
- Table Down 100 mm (Factory option)
- Oscilloscope
- Active Power Restart (UPS)
- Automation system
- 8-axis simultaneous control SP-E (Factory option)
- Custom Colour
LED lights on both machine sides and head
Blue:
on stand-by
Green:
during operation
& program running
Red:
program stopped
Technical Specification | AL40G |
| XY axis travel | 400 x 300 mm |
| Z axis travel | 270 mm |
| C axis head angle indexing (2 options) | SEC-10: 0,001º (3,6″) or SCR72P: 1/720000° |
| C axis head rotation speed (2 options) | SEC-10: 2 – 20 rpm or SCR72P: up to 2000 rpm |
| Work table dimensions (Sodick Ceramics) | 600 × 400 mm |
| Work tank dimensions (W x D xH) | 750 x 620 x 350 mm |
| Work Tank Fluid Level (Min to Max) | 100 ∼ 300 mm |
| Work Tank Capacity | 190 Liters |
| Distance from clamp chuck to table top (EROWA COMBI / EROWA ITS) | 150 ∼ 420 mm |
| Distance from clamp chuck to table top (3R COMBI / 3R MACRO) | 133 ∼ 403 mm |
| Max workpiece weight | 550 kg |
| Max electrode weight | 50 kg |
| Distance from floor to table top | 830 mm |
| Machine Tool Dimensions (W x D x H) (Including a Power Supply and Dielectric Tank) | 1,675 x 2,600 x 2,330 mm |
| Machine installation dimensions | 2525 x 3,535 mm |
| Machine tool weight | 4,100 kg |
| Total power input | 3-∅, 50/60 Hz, 10 kVA |
| Air pressure / flow | 0.65 MPa /100NL/min |
Technical Specification | AL60G |
| XY axis travel | 600 x 420 mm |
| Z axis travel | 370 mm |
| C axis head angle indexing (2 options) | SEC-10: 0,001º (3,6″) or SCR72P: 1/720000° |
| C axis head rotation speed (2 options) | SEC-10: 2 – 20 rpm or SCR72P: up to 2000 rpm |
| Work table dimensions (Sodick Ceramics) | 750 × 550 mm |
| Work tank dimensions (W x D xH) | 950 x 740 x 450 mm |
| Work Tank Fluid Level (Min to Max) | 200 ∼ 570 mm |
| Work Tank Capacity | 330 Liters |
| Distance from clamp chuck to table top (EROWA COMBI / EROWA ITS) | 200 ∼ 570 mm |
| Distance from clamp chuck to table top (3R COMBI / 3R MACRO) | 183 ∼ 533 mm |
| Max workpiece weight | 1,500 kg |
| Max electrode weight | 50 kg |
| Distance from floor to table top | 850 mm |
| Machine Tool Dimensions (W x D x H) (Including a Power Supply and Dielectric Tank) | 1,875 x 2,930 x 2,570 mm |
| Machine installation dimensions | 2,600 x 3,850 mm |
| Machine tool weight | 5,350 kg |
| Total power input | 3-∅, 50/60 Hz, 10 kVA |
| Air pressure / flow | 0.65 MPa /100NL/min |
Technical Specification | AL80G |
| XY axis travel | 850 x 520 mm |
| Z axis travel | 420 mm |
| C axis head angle indexing (2 options) | SEC-10: 0,001º (3,6″) or SCR72P: 1/720000° |
| C axis head rotation speed (2 options) | SEC-10: 2 – 20 rpm or SCR72P: up to 2000 rpm |
| Work table dimensions (Sodick Ceramics) | 1,100 × 700 mm |
| Work tank dimensions (W x D xH) | 1,400 x 950 x 500 mm |
| Work Tank Fluid Level (Min to Max) | 250 ∼ 670 mm |
| Work Tank Capacity | 690 Liters |
| Distance from clamp chuck to table top (EROWA COMBI / EROWA ITS) | 250 ∼ 670 mm |
| Distance from clamp chuck to table top (3R COMBI / 3R MACRO) | 233 ∼ 653 mm |
| Max workpiece weight | 3,000 kg |
| Max electrode weight | 100 kg |
| Distance from floor to table top | 840 mm |
| Machine Tool Dimensions (W x D x H) (Including a Power Supply and Dielectric Tank) | 2,160 x 3,225 x 2,900 mm |
| Machine installation dimensions | 3,100 x 4,570 mm |
| Machine tool weight | 9,800 kg |
| Total power input | 3-∅, 50/60 Hz, 11 kVA |
| Air pressure / flow | 0.65 MPa /100NL/min |
| CNC Power Supply SP/SP-E | |
| Max. machining current | AL40G: 40A |
| Discharging power supply unit | Optimum pulse control for TMM 4 power supply (SGF, BSN4, SVC) |
| CNC unit | Multi-tasking OS, M4-LINK system |
| Memory device | SSD card, External USB stick |
| Input | External memory, Touch panel screen, Keyboard |
| Display | 19” TFT-LCD (XGA) |
| Keyboard | Standard 101-key, Alphanumeric and symbols, Function key |
Remote controller (standard) | Standard jog (switchable), Assist A0 to A3, Clamp / Unclamp,etc. |
Positioning command | Incremental and absolute, |
Simultaneous control axes | 4 axes XYZC (max. 8 axes with SP-E=option) |
Min. drive unit / input command | 0.01 µm / 0.001 µm |
AJC speed (max) | XY axes = 10 m/min // Z axis = 36 m/min (600 mm / sec) |
Position detection mechanism | Full closed loop (Absolute Linear scales 0,01 µm=10 nanometers) |
Compensations | Pitch error, plane pitch error and torque corrections for each axis |
| Dielectric Tank | |||
| Model | AL40G | AL60G | AL80G |
| External dimensions (W x D x H) | built-in | built-in | 2,060 x 1,140 x 2,230 mm |
| Tank weight | built-in | built-in | 600 kg |
| Tank Capacity (liters) | 285 l | 465 l | 845 l |
Required amount of dielectric fluid (liters) | 330 l | 560 l | 1000 l |
| Dielectric fluid | EDM Oil preferably with Flash Point ( PMCC, °C, Min.) = 110°C. We recommend EDMfluid® 108MP-S (Steelfluid/Italy) | ||
| Filtering system | 2 Replaceable paper filter (MF-2400, Pressurized) or similar | 4 Replaceable paper filter (MF-2400, Pressurized) or similar | |
Highly Rigid Structure
"TH COM"
Together with a highly rigid machine structure, the adoption of precision correction function “TH COM” reduces the amount of thermal displacement by 50% compared to conventional models.
The Sodick Linear EDM AL-G series is equipped with the new precision thermal compensation system “TH COM”* as standard.
Temperature sensors are installed throughout the machine body and the CNC records the temperature fluctuation. It automatically compensates the axes movements tominimise the thermal displacement. The recorded temperature data can be displayed on the controller screen
The Sodick Linear EDM machine cast construction is designed with heavily ribbed sections to provide superior long-term rigidity and stability. The surfaces to which the THK SSR Type Ball-Type Linear Guideways, are mounted on scraped by hand surfaces to ensure a perfectly flat surface and outstanding machine geometry + longevity.
Aero Harmonic System:
In the new Sodick Linear EDM is provided in-machine air & dielectric circulation system to maintain the internal and external temperature of casting.
Construction Features
Renewed CE door with new design on AL-G series.
The counter balance system is adopted, realising a longer life of the door
COMPACT CONSTRUCTION
Common design features of all Sodick EDMs:
Meehanite® cast iron with a low thermal expansion of 11×10-6/°C in all machine-tool bearing structures (bed, column, table carriage, taper mechanism trusses).
Hand-scraped contacting bearing surfaces
for the linear guides and the contacting surfaces of the bearing structures being assembled. Manual precision scraping of cast iron after milling. Manual scraping prevents deterioration of the machine structure, which is inevitable if the contacting bearing surfaces are ground rather than scraped.
I.
Only HAND SCRAPING eliminates waveness that inevitably arises on surfaces as a collateral result of milling.
II.
Only HAND SCRAPING eradicates microcracks, burnings, internal stresses and eliminates charging (impregnation) of surfaces with microabrasives.
III.
Only HAND SCRAPING can make it possible to build machine-tools with long-life accuracy lasting for decades.
High-torque precision flat linear motors (LMs) of Sodick in-house design and manufacture, starting with in-house rare earth Ne-Fe-B magnets.
Flat or planar linear motors with core coils inherently provide a substantial power and thrust reserve. This not only improves rapid movement and positioning accuracy but also ensures consistent performance under varying load conditio
The design of Sodick’s planar linear motors ensures minimal heat generation. This is a major advantage, especially in precision applications like EDM, where even slight thermal variations can affect accuracy.
Flat (planar) linear motors (LM) with core EM coils mounted on cast iron supporting structures have excellent heat dissipation and virtually no heating under light loads. However, in die-sinking EDMs, the LMs operate under prolonged excessive loads (relaxation in Z and oscillation in XY), which means that heating is inevitable. To prevent overheating, all Sodick die-sinking EDMs are equipped with an effective patented LM cooling system (pumping of lubricant through tubes around the EM coils).
The use of a specialized cooling system, particularly one that is patented and designed explicitly for the unique requirements of their die-sinking EDMs, showcases Sodick’s commitment to producing machines that deliver optimal performance across a range of conditions. It is these kinds of innovations that help manufacturers maintain a competitive edge in the market.
By incorporating in-House ceramic components into their EDMs, Sodick ensures a higher level of precision and consistency in the machining process. The improved geometric accuracy of the electrode position relative to the workpiece can result in better part quality, reduced waste, and increased efficiency in the machining process.
The thermal expansion of all supporting structures of the work zone is 2 times less than that of granite and 3.5 ∼ 4 times less than that of steels, thanks to our own electro-insulating ultra-strong ceramics FineXCera® with ultra-small thermal expansion = 4.5 × 10-6/ °С
Sodick ceramics are extremely rigid and can resist bending or deformation under load. This property ensures that the worktable and electrode plates remain flat and stable during the EDM process, leading to more consistent and accurate results.
As non-conductive materials, Sodick ceramics provide excellent electrical insulation, which is crucial in the EDM process to ensure that electrical discharges occur only where intended.
Achieving complete galvanic isolation of the machined part in all Sodick EDMs has several benefits:
- Enhanced Sparking Capabilities: If a machined part is not in contact with the ground, it provides the opportunity to generate spark pulses that may be impossible on machines with a metal table where the workpiece is grounded. This leads to unique machining characteristics and outcomes that aren’t achievable with traditional grounded setups.
- Efficient Use of Bipolar Pulses: Bipolar pulses involve the use of both positive and negative voltage swings. Without the grounding restrictions, the EDM utilizes these bipolar pulses more effectively, potentially leading to faster material removal rates, better surface finishes, or other desired machining characteristics.
- Special Pulse Utilization: Beyond just bipolar pulses, galvanic isolation can allow for the implementation of other specialized pulse types. Each pulse type can have its own characteristics in terms of material removal, surface finish, and machining efficiency.
- Safety and Protection
- Reduced Electrical Noise
- Enhanced Control: a wider range of machining parameters and potential outcomes based on the specific needs of the job.
By having an EDM setup that offers complete galvanic isolation, manufacturers and machinists can potentially push the boundaries of what’s possible with EDM, experimenting with and benefiting from pulse types and parameters that may be unavailable or less effective in traditional grounded setups.
