Offline programming solutions software from Makino can help reduce human error in burn programs, in turn reducing scrapped mold components and increasing machine shop efficiency, driving out operational costs. EDcam™ software relays critical data between CAD-CAM systems and sinker EDM machines, bypassing the need for manual input, which often leads to operator errors and mistakes.
This new software enhances sinker or Ram EDM capabilities through the direct reception and proper calibration of workpiece data as a critical relay between the machines and CAD-CAM systems. It receives all necessary peripheral information from the CAM systems, such as electrode positioning, and adds the necessary burning technology and tool change data to output a final numerical controlled (NC) program for the EDM machine to utilize.
With the EDcam™ software, this information is taken directly from the part drawing or CAD-CAM system and dumped into the burn program without any human intervention. This essentially provides machine shops full offline programming capabilities, making CAD-CAM departments more versatile and operators more efficient.
Reducing Manufacturing Costs and Time to Market
The EDcam™ software technology allows die/mold shops to use machines more cost effectively, drive out operational costs, reduce lead time, and quicken product time to market. EDcam™ inputs position points from a design system directly into a burn program. In addition to translating positioning data, the software helps operators determine critical burn parameters, such as electrode material and quantity, undersize parameters, desired removal rates and surface finishes. This technological advancement creates burn parameters that in the past could only be determined by an operator with several years of experience.
For example, an operator typically uses the EDM machine to complete a job before using the same machine to pick up all the electrodes and workpieces required for the next burn. This process ties up valuable machine resources and increases cycle time. With EDcam™ software, an operator can pick up electrode offsets and workpieces offline on a coordinate measuring machine and have the data transferred to the program for use.
An operator can start a burn program on a machine and then prepare future burns on a remote computer and send them directly to the machine with EDcam™. Then all the operator needs to do is to push the start button.
The software allows shops to plan ahead for the next job while a current job is being done, and manipulates the data in a much more efficient flow. Because the software takes control of the programming process, running the EDM machine does not require a highly skilled applications engineer or mold maker. In fact, operators who have little or no training on an EDM machine can develop burn programs using EDcam™.
Unmanned Operations
Automation systems for EDM production teamed with advanced software such as EDcam™ do require machines with high rigidity for the best accuracy and performance. Multi-directional burning with identical servo performance, a disappearing drop tank, complex orbit control, interactive automatic programming, and an adaptive control system that reduces or eliminates active flushing are critical elements to EDM automation with EDcam™.
Unmanned operations create the optimum system for small-lot, large variety production, which readily accommodates production change priorities. It also helps maintain efficient throughput, utilizing less floor space and allowing the timely transfer of jobs to the next process. The manufacturing process may become more streamlined and efficient, and time-consuming operations like job setup, alignment, positioning, programming, removal, and cleanup can all be eliminated with EDcam™.
