HS-Rib Z-Axis Sinker EDM Technology

November 01, 2014

Makino announces its new HS-Rib high-speed Z-axis technology for reportedly improved speed, lower electrode wear and more uniform finishes in large sinker EDM processes. When it comes to reducing sinker EDM cycle times, it is not the maximum jump speed that is important, but rather the acceleration speed. Makino's new high-speed Z-axis technology has a jump rate four times faster and Z-axis acceleration rate 30 times faster over previous technologies. This capability produces a more efficient hydraulic effect during machine processing, which helps evacuate debris from the spark gap, even in deep-rib features.

"As with all machining processes, there's an insatiable desire to reduce cycle times while meeting part-quality requirements in sinker EDM processing," said Brian Pfluger, Makino's EDM product manager. "Fulfilling these needs involves a number of considerations, including how to process for best speed and efficiency, minimize electrode manufacturing requirements, and reduce electrode wear to achieve the best possible surface finish quality. Our new high-speed Z-axis technology, combined with Makino's SuperSpark IV, helps support these factors, providing an ideal balance for efficiency in both electrode consumption and cycle times without the need for external auxiliary flushing."

The new high-speed Z-axis technology is available on all Makino EDNC-Series sinker EDM machines, and is designed for use in large workpiece applications requiring high accuracy and fine surface finishes. Its design offers highly flexible processing capabilities, including a jump rate of 20 m per minute with 1.5-G acceleration, Z-axis strokes ranging from 500 to 800mm, and programming of orbital machining patterns with no amperage limitations. The use of direct-drive motor technology and liquid cooling within the Z-axis structure ensures sustained thermal stability and precise depth control, and supports electrode weights of up to 100kg (220 lbs.).

Makino also offers the following four process strategies for optimal performance based on users' unique requirements for speed, surface quality, accuracy and electrode wear:

• Low Wear Settings: Provide a single-electrode rough and finish process

• Advanced Orbit and Jump Settings: Improve machining speeds and surface finish consistency

• High-Speed Z-Axis: Improve machining speeds and accuracy

• Aggressive Power Settings: Optimize machining speed (sacrifices electrode wear)

Makino's EDNC-Series sinker EDM machines combine rigid and precise construction, simple programming and advanced performance features for accurate EDMing of large workpieces. Equipped with the new high-speed Z-axis technology, these large, heavy-duty machines can produce deep ribs as fast as, or faster than, the smallest sinker EDM machines on the market. Automatic tool change and adaptive controls enable high levels of unattended machining without the need for operator intervention, and is further supported with advanced automatic jump machining controls to optimize debris removal without the need for external flushing.

EDNC sinker EDMs are designed with several friendly and efficient features. The machine uses a space-saving design that incorporates the dielectric reservoir into the base casting, which saves on floor space while also improving the thermal stability of the machine. Most EDNC-Series machines have a full three-sided programmable drop tank with unparalleled ergonomic access to the machine for setups and operation. All machines feature fully automatic fire-suppression systems, and use a special UV sensor that affords an excellent first line of defense for added operational safety. Programming can be performed using the menu-driven touch screen advanced model plan or streamlined MPG conversational format systems. Both methods offer simple selection of machining conditions for workpiece and electrode material type, and the desired feature shape and surface finish. The machine also is designed with advanced menu-driven 2-D and 3-D orbital motion techniques that provide high accuracy and uniform surface finish results over the entire workpiece detail regardless of complexity.

All EDNC-series sinker EDMs can be equipped with Makino's proprietary High-Quality Surface Finish (HQSF) technology that yields achievable surface finish capabilities 50 percent better than that of conventional surface finishes, regardless of discharge surface area. Even when machining to standard/conventional surface finishes, the HQSF technology can yield a double-digit saving in cycle time.

Related Glossary Terms

  • 2-D


    Way of displaying real-world objects on a flat surface, showing only height and width. This system uses only the X and Y axes.

  • 3-D


    Way of displaying real-world objects in a natural way by showing depth, height and width. This system uses the X, Y and Z axes.

  • electrical-discharge machining ( EDM)

    electrical-discharge machining ( EDM)

    Process that vaporizes conductive materials by controlled application of pulsed electrical current that flows between a workpiece and electrode (tool) in a dielectric fluid. Permits machining shapes to tight accuracies without the internal stresses conventional machining often generates. Useful in diemaking.

Additional Products from Makino Inc.

Makino announces the F5 Pro6 vertical machining center designed to provide stiffness and rigidity for chatter-free cutting, agility for high-speed/hard-milling and accuracies for tight tolerance blends and matches typical of complex, 3D contoured geometry associated with die/mold and medical Read More
To be competitive in the marketplace manufacturers must continuously identify opportunities to improve efficiency and increase capacity while maintaining the highest level of quality. Makino is introducing a new wire EDM machine – U6 H.E.A.T. Extreme – that delivers these requirements with Read More
With the release of HyperConnect, Makino offers a suite of industrial internet of things (IIoT) applications for electrical discharge machines that enhances user experience and efficiency, and reduces machine downtime. Available on all Makino EDMs equipped with Hyper-i control systems, HyperConnect Read More
Makino offers EDGE-Series machines, the EDGE2 and EDGE3, to the U.S. manufacturing market. Built for general precision machining applications, both EDMs provide accurate and reliable performance for standard die/mold components or contract manufacturing with a space-saving design for shop floors of Read More
Makino offers the next-generation MAG3.EX 5-axis horizontal machining center, a machine platform updated with expanded capabilities for the processing of complex aluminum structural parts for the aerospace industry. With its speed, power and motion control enhancements, the new MAG3.EX provides Read More
The increasing complexity of modern tool, die, mold and medical part designs call for a new level of 5-axis machine performance. The Makino D200Z 5-axis vertical machining center reportedly answers these challenges by combining the quickness of machine movements and accuracies with the latest Read More
Building on its PS-Series product line, Makino announced the next-generation PS65 and PS105 vertical machining centers. Both models feature enhanced design characteristics and next-generation technologies that expand upon the capabilities of their predecessors.
Makino introduces SGI.5, its latest version of Super Geometric Intelligence software for high-feed rate, tight-tolerance machining of complex 3D contoured shapes. Depending upon the specific geometry of the application, SGI.5 can provide 20 to 60 percent faster cycle times while maintaining Read More
Automation is essential in helping manufacturers achieve maximum return on investment from their machine tools. Makino offers the availability of a new design configuration for its MMC2 automated pallet-handling system, which enables full compatibility with the company’s a61nx-5E 5-axis horizontal Read More
To address the need for high-quality hole drilling of turbine engine components, Synova and Makino are joining forces to offer the HybridCell, which combines the power of Synova’s Laser MicroJet (LMJ) with Makino’s leading edge EDM capabilities. It is a fully automated, manufacturing-ready, work Read More