Sodick Co., Ltd. has released the AX350L i Groove + Edition linear motor drive ultra-precision wire electrical discharge machine. Primarily, the new EDM is equipped with a wire rotation mechanism and energy-saving functions to meet a variety of high-precision machining needs.

AX350L iG+E is scheduled to be exhibited at “JIMTOF2024” (Nov. 5 to 10 at the Tokyo Big Sight).

For more than 40 years since Sodick started sales in 1981, its oil-based wire electrical discharge machines have been used by customers around the world in a wide range of fields, including automobiles, watches, medicine, and semiconductors. In recent years, there has been an increasing demand in these industries to improve production efficiency through continuous processing over several days, to improve work convenience and maintainability, and to save labor.

To flexibly respond to such diverse high-precision machining needs, Sodick has developed the ultra-precision wire electrical discharge machine AX350L iG+E. Primarily, it features improved performance than the conventional machine AX350L. Also, it is equipped with a wire rotation mechanism and energy-saving functions. Moreover, AX350L iG+E realizes high-quality, high-efficiency production of a variety of high-precision molds, from small electronic parts and mold parts to drive parts and plates for medium-sized automobiles, such as motor cores.

Development Points

Review the mechanical structure and increase mechanical rigidity

Particularly, AX350L iG+E features a revised mechanical structure of the conventional model AX350L to further increase mechanical rigidity. Sodick has created a structure that minimizes mechanical displacement based on advanced structural analysis technology, thermal displacement simulation, and actual measurement data and machining results from numerous machines in actual machining site environments.

In addition, based on the idea of ​​comprehensive temperature control, the company has added a new control mode to its proprietary thermal displacement correction system “TH-COM”. This is in addition to adopting a high-rigidity gate-type structure and environmental diagnosis function. Moreover, it has added a new control mode to the workpiece and processing fluid. With the precision temperature control function centered on, it is possible to stably perform mold plate processing over long periods of time.

Achieves processing that suppresses wire breakage even with high energy

On the machining surface, by controlling the electrical discharge waveform during rough machining in wire electrical discharge machining more precisely than before, it is possible to achieve machining that suppresses wire breakage even with high energy.

Sodick’s unique “wire rotation mechanism” eliminates the effects of electrode wear on machining by gently rotating the wire. Particularly, this new technology allows the workpiece to be machined from top to bottom using an unconsumed wire surface. Thus, it results in stable high-precision machining dimensions and a uniform, high-quality machined surface. Also, this technology reduces wire consumption by increasing processing speed and effectively utilizing the entire circumference of the wire electrode, contributing to lower running costs and ecology. Wire reduction effect of up to 30% is achieved in the finishing machining area.

Reduce power consumption by 10% compared to conventional models

In wire electrical discharge machining, the power used for machining fluid treatment systems such as jet flow, machining fluid circulation, and optimal machining fluid temperature adjustment is greater than the power required for the machining itself, and reduction is important.

Primarily, AX350L iG+E monitors the flow rate (jet flow/circulation) of machining fluid and optimally controls machining fluid circulation and liquid pump depending on machining conditions, reducing power consumption by 10% compared to conventional models. (Comparison with *AP350L). In addition, it is equipped with a gadget function called “eco collections” that allows users to turn On/Off automatic power shutoff with a single touch and display running cost status in real time. Sodick helps its customers reduce CO₂ emissions and power consumption, realizing environmentally friendly and sustainable production.

Supporting smart manufacturing

In recent years, there has been a need to improve productivity through continuous automatic operation during weekday nights and weekends. Specifically, the AX350L iG+E is equipped with a fully automatically controlled three-sided automatic up/down tank, and is compatible with a workpiece exchange system using a robot. It is a highly compatible machine that can create continuous automatic operation. Equipped with a data connection interface to the production system based on the international standard MT Connect/OPC-UA, by combining the output data from “AX350L iG+E” with the customer’s skills and know-how, the company is ready to enter the era of digital transformation, supporting smart manufacturing.

Markets and Fields

The new electrical discharge machine suits manufacture of press molds for motor cores that are directly linked to the performance of driving motors in EVs (electric vehicles). It is also designed for molds for semiconductor package lead frame manufacturing, etc.

Main equipment features

(1) Long-term stable processing

Plate processing of precision stamping dies can take up to 150 hours (about a week), and these processes can be operated continuously automatically.

4-axis X, Y, U, and V axis linear motor drive (excellent positioning performance and reproducibility)

High-rigidity gantry structure

Comprehensive temperature control (processing fluid temperature control, precision thermal displacement correction function, environmental temperature diagnosis)

Constant liquid temperature control mode can be applied to the precision thermal displacement correction function.

Arm suspension structure (the lower arm does not penetrate the processing tank, and there is no sliding resistance when moving the axis)

Standard use of ceramic structural members for stable fine discharge (surface plate, work stand)

Oil working fluid specification (micromachining with a stable discharge gap)

(2) Work setup performance

Thanks to its excellent accessibility, it is easy to change, install and position the workpiece in all processing areas.

The machining tank is lowered to the bottom of the workstand (easy removal of high-thickness cut-off parts)

Increased visibility from the top of the workpiece (including Z-axis stroke 220 mm < service stroke of 100 mm>)

Easy loading and unloading of workpieces (designed to secure space for the use of hand lifters)

(3) High-performance functions, ultra-precision machining performance

High-speed automatic wire termination system FJ-AWT (wire straightening function, pilot hole search function)

Best-in-class pitch and shape accuracy ±1μm

Surface roughness Ra 0.02μm Rz 0.18μm

(4) Maintainability

Suction-type wire discharge mechanism (beltless system reduces the number of parts to be replaced periodically)

 (5) Enhanced automation and labor-saving

It is possible to construct a workpiece exchange system using robots.

Various useful functions such as pitch processing correction function and idling function

 (6) Environmentally friendly and sustainable production

Gadget function “eco collections” (running cost display, etc.)

Energy-saving function due to optimal control of processing fluid

Reduction of wire consumption by wire rotation mechanism “i groove”

This is an online translation of a Japanese press release with slight editing made by Dempa.

-06 November 2024-