Progress in Mold Technology Promotes Improvement of Electrical Machine Tool Performance
1 Introduction Figure 1 ACTSPRK CNC Precision Electric Discharge Machine SA Series 2 CNC EDM machine performance gains in mold manufacturing Figure 2 mirror processing sample Figure 3 processing Huff pen model 2.3 Increased degree of automation Nitrogen Generator For Powder Metallurgy Nitrogen Generator For Powder Metallurgy,Well-Qualified Nitrogen Generator,Industrial Grade Nitrogen Generator,Professional Nitrogen Generator Jiangsu Minnuo Group Co.,Ltd , https://www.mnuogroupcn.com
In recent years, the rapid development of the mold industry has brought new challenges to mold technology. EDM has always been a core part of the mold technology, especially in the injection mold manufacturing plays a pivotal role. At present, advances in high-speed milling technology have replaced some of the EDM processes in the mold manufacturing, so some people think that its development trend will replace EDM. However, if we carefully analyze the advantages and disadvantages of these two major mold forming technologies, we can find that high-speed milling machining is not a substitute for EDM because of the constraints of the milling process itself. Deep groove slits, clear corners, sharp edge processing, subtle, complex, precision machining, deep cavity machining, and super-hard material processing are the missing features of high-speed milling capabilities. On the contrary, EDM has an absolute advantage. In addition, under the influence of the new situation in the development of CNC technology, EDM has developed rapidly in the direction of deeper and higher level CNC. Nowadays, new types of CNC EDM machines have emerged in an endless stream. The performance of various brands of CNC EDM machines has been fully enhanced. The following is an example of the new SA series products of the Beijing ACTSPRK CNC precision EDM machine tool (figure 1), to introduce the performance improvement of CNC EDM machine tools in mold manufacturing. 
2.1 Improvement of machining accuracy
The large-scale development of the mold industry, the higher and higher requirements on the accuracy of the mold. High-precision molds such as miniature connectors, IC plastic molds, cell phones, CD boxes, etc., have become very popular mold varieties on the market. The precision of EDM for these molds has been comprehensively improved. The dimensional processing requirements can reach ±2-3μm, the R value of the bottom corner is less than 0.03mm, the processing surface roughness is as low as Ra0.3μm, and even the mirror processing is required. The improvement of die EDM accuracy has benefited from the improvement of the accuracy of CNC EDM machines. Because the use of machine tools for processing, machining accuracy can not exceed the accuracy of the machine. Therefore, the general discharge machine is difficult to complete high-precision EDM. Selecting a good discharge machine is the premise to ensure the machining accuracy. The ACTSPRK CNC precision electrical discharge machine SA series uses the core technology of the Agie Charmilles Group, which greatly improves the quality of CNC EDM. Machine rigidity is good, short C-shape design guarantees precise discharge gap; Swiss pulse power supply can achieve stable processing under small clearance; X, Y, Z DC motor drive ensures high-precision positioning, high-performance servo control system can The processing depth error is controlled to a minimum to achieve high-precision machining; the rich translation method is used to accurately compensate the profile contour size; the electrode loss during finishing is small, the finishing module meets the mirror processing requirements, and a high-grade surface can be processed CNC automatic processing greatly reduces the dependence of processing precision on man-made.
2.2 Improvement of processing efficiency
Modern molds require EDM to substantially increase the efficiency of roughing and finishing while ensuring accuracy. For example, mobile phone housings, household electrical appliances, electrical appliances, and electronic instruments all require the discharge time of large-area workpieces to be significantly shortened, while at the same time reducing roughness. Some molds require no manual polishing after discharge, which not only shortens the processing time but also eliminates the trouble of post-processing, and at the same time enhances the mold quality. These efficiency requirements place higher demands on the performance of CNC EDM machines. ACTSPRK CNC Precision Electric Discharge Machine SA series uses pure Swiss imported pulse power to greatly increase the productivity of machining. AEP automatic programming system has enhanced the retrieval function of the processing conditions, and can switch the multi-segment processing conditions. By switching the multi-segment processing conditions, it is possible to carry out the processing of the best margin under each condition, which can shorten the processing time and improve the machining accuracy. Such as the use of Φ20mm copper electrode in 4Cr5MoSiV1 steel processing 0.5mm depth, to achieve a mirror effect (about Ra 0.1μm) only 3.5 hours (Figure 2); transverse processing Huff pen mold cavity processing time of 0.8 hours, fine It took only 1.2 hours to achieve a finish of Ra 0.8 μm. In addition AEP automatic programming function reduces the programming auxiliary time, the friendly man-machine contact surface makes the operation very quick, also improved the processing efficiency to a certain extent. High-efficiency CNC EDM machines are the capital for mold companies to expand their market space and increase their market competitiveness. The new products and new technologies they have developed are also more popular. 
At present, the automatic performance of advanced CNC EDM has been fully improved. ACTSPRK CNC precision precision electrical discharge machine SA series can be equipped with AEC (electrode automatic exchange device) and quick clamping positioning system (EROWA, 3R), so that the entire EDM machining as long as the electrode is loaded into the tool store before processing, prepare a good processing program , it can be automatically operated, using the reference ball and the probe for positioning, automatic measurement and correction of the electrode and workpiece position in the processing, monitoring and processing, without manual operation, breaking the traditional processing of cumbersome operation mode. In addition, the machine has the functions of automatic center finding, center finding, angle finding, automatic parallelism of the electrodes, C-axis rotation coordinate system, no need of correcting workpieces, continuous machining of multiple workpieces, etc., all reflecting the high level of automation performance of CNC EDM. The automation performance reduces the labor intensity of the operator, improves the production efficiency, and improves the machining accuracy.
2.4 The degree of intelligence upgrade
Most of the new CNC EDM machines use intelligent control technology. With the increase of EDM requirements in the market, intelligent technologies are constantly being upgraded. The NC software of the ACTSPRK CNC precision electrical discharge machine SA series is based on the WINDOWS XP platform. The human-machine interface is friendly, the degree of intelligence is high, and it is easy to learn and use. AEP automatic programming system adopts man-machine conversation mode. During the programming process, as long as you press the system prompt step to create relative zeros, create machining positions, and create electric discharge machining, automatic program generation can be realized without memory of any code; as long as reasonable during the creation of electric discharge machining process Input or select the process data can automatically detect the best processing conditions in a rich process parameter library, such as selection of translation method, electrode and workpiece material, target roughness value, input processing depth, electrode bottom area, taper value, electrode scaling Quantity and other indicators; AEP automatic programming system has a wealth of processing strategies, can get the ideal processing results, such as the choice of standard, low-loss, high-efficiency discharge mode, can be divided into standard, standard no blunt, sharp, narrow slit , perforation and other process types; when processing variable cross-section electrodes, according to the processing area and processing depth changes, automatically select the processing conditions; programming can be programmed after the program can be performed, and can be checked through the image display; processing The status of EDM gaps is determined by computer monitoring, along with processing Ranges of carrying knives adaptive, intelligent control of the process. The upgrading of the degree of intelligence makes the operation of the machine easier and requires less technical skills for the operator.
2.5 Other performance improvements
The improvement of CNC EDM performance includes many other aspects. The ACTSPRK series of precision CNC electric spark machine SA series can realize four-axis and four-linkage machining in terms of expanding applications. For example, it can process complex workpieces such as external threads, internal threads, three-dimensional helical surfaces, etc.; it adopts automatic fire detection devices and liquid level detection devices for safety. , to prevent collision function; energy saving is particularly significant, similar product capacity of 10 ~ 15KVA, while the SA power is only 3.7KVA, saving more than half of the electrical energy.
3 Conclusion
With the rapid development of mold technology, CNC EDM has achieved breakthroughs. EDM machine tool performance has also been fully improved, in the impact of high-speed milling technology development, EDM machine manufacturers will continue to improve production technology, greatly improve the CNC EDM machine processing quality, processing efficiency, so that This special processing technology is invincible in the mold manufacturing.