5g FHD XL 5 Axis EDM System

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EDM Drill 3D Shaped Holes in Aerospace and Land Based Gas Turbine Blades and Components!

Our 5 Axis fast hole EDM XL Drilling Machines provide precision 3D shaped hole burning capabilities, ideally suited for machining large and heavy aerospace engine and gas turbine components. With 36” of X Axis EDM travel, and state of the art features, this user friendly machine offers a flexible, cost effective solution to your Aerospace manufacturing needs. A robust, custom trunnion type tilt turn table with a stainless steel Erowa chuck allows for quick change over of part holding fixtures. The rotary axis are so configured to allow the work piece to be centered on both axis, reducing the distance traveled on the linear axis and increasing machine capacity and efficiency. The 5g Tech-Pulse EDM Generator has the ability to store up to 500 process parameter programs, with the ability to adjust the process parameter up to four times during the drilling of a single hole. A key feature of the Tech-Pulse Generator is its process analysis capability. The process is graphed showing a depth against time thumbprint, which allows the operators to easily develop new process parameters as necessary. This machine is enclosed in a custom designed machine enclosure with access via horizontally sliding doors with safety switch.

Fast Hole EDM Drilling

Linear Stroke Specifications

-X Axis: 36.00”
-Y Axis: 23.00”
-Z Axis: 15.00”
-A Axis: 360º (Rotary)
-B Axis: +/-180º (Tilt)
-EDM Stroke: 18”

Machine Specifications

-Req’d Floor Space: 10.08’×6.75’
-Max Work Envelope: 26”Ø×15”
-Max Part Weight: 250lbs

Accuracies:
-Linear:
10 µ (+/-.0004”) Accuracy
5 µ (+/-.0002”) Repeatability
-Rotary:
+/-25 arc seconds Accuracy
25 arc seconds Repeatability

Standard Key Features

-3D Shaped Hole Machining
-Quick Change Guide & Electrode
-18” Electrode Length Capability
-Hole Size .25-10mm Ø
-Process Thumb Printing
-Fast Break Through
-Pre-Break Through Detection
-Break Through Detection
-Built in Heidenhain Probe
-Deionized Dielectric Plant

Customization Options

-Auto Part Load and Unload
-Automatic Electrode and Guide Changing
-Crash Protection
-Laser Ablation

PROBING SYSTEM

The machine is fitted with a Heidenhain probing system. This is mounted on an automatically extending probe arm, which is activated by the CNC control. This probe is used in three main ways:

1. Machine Check
A four minute CNC probe cycle checks out the accuracy of all 5 machine axis and also sets the zero datum points for all axis. This cycle enable the machine to be checked for geometrical accuracy on a daily basis and can be used to check for machine damage after a tooling crash.

2. Part Set
Built-in cycles in the control system enable the probe system to be used to “find” the Part. This is done using a 5-point probing routine (3+2-Plane-Line, 6th Point defined by the fixture). The advantages are:

· Fixturing becomes lower cost
· Multiple sets of datum’s can be used with re-fixturing
· Parts cannot be miss loaded and machined
· Improved Accuracy

3. Electrode Set
A special calibrated machined bore is probed and measured for position and diameter, each electrode tool as it is loaded is then “contact sensed IN” and the electrode is checked for diameter and position, an automatic tool offset is applied to the tool which compensates for any small positional error in the electrode position, this is especially useful when using long electrode guide holders.

Step 1: Check and Set the Machine

All axis are checked for positioning accuracy, datums are set and the part pallet chuck geometry is checked. This daily check ensures the machine can achieve maximum accuracy before being used.

Step 2: Electrode Position Set

The electrode position is now measured to the machine datum and tool offsets are automatically applied.

Step 3: Locate the Part Datums

The part is probed on its datums, “nested” by the software and then rechecked by the probe. Multiple datum’s can be used within one operation. For example, when multiple aerofoil offsets need to be applied.

4” OR 8” CRASH PROTECTION SYSTEM

This wireguide extension is designed to introduce the wireguide to difficult positions on a part needing 3D holes drilled with EDM. This ability also helps with access to more holes in a part in one fixturing. Built within this assembly is a mechanical breakaway and return mechanism that protects the machine, part and guide from damage in the event of a crash. When contact is made between the machine or part and the guide area, a mechanical micro switch will sense movement of the crash protection arm and shut down the drives and EDM as well. After recovery, all positioning is reconfirmed functionally correct and production can resume.