Sodick Die-Sinking Electric Discharge Machines
Sodick EDM service and maintanence
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.
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.