EDM EDM drilling — Company manufacture of excellent drill holes
EDM drilling makes it potential to supply the smallest drill holes, unbiased of fabric hardness. CFK meet the necessities of their clients for machining of their workpieces each day.
CFK, a service supplier primarily based in Kriftel, Germany, is extremely specialised within the fields of wire-cutting, die-sinking, EDM drilling and additive manufacturing. They’ve been working within the subject of electrical discharge machining (EDM) for greater than 30 years. In consequence, they dispose over a variety of EDM drilling applied sciences and huge expertise. Some 70 workers manufacture very small to very large elements — beginning with surgical grippers within the micrometre vary as much as turbine elements and form plates, which may have a weight of as much as 4 t.
The portions obtainable vary from single items to serial manufacturing of 500,000 elements and extra. One specific ability of CFK is EDM drilling. Right here, begin holes for wire chopping are machined alongside particular person drill holes in numerous drilling angles and single and serial elements with advanced gap patterns. Begin-hole drilling is required for subsequent processing with wire-cutting machines. For easy workpieces, the beginning holes are manufactured manually, whereas for advanced elements a program is generated from CAD/CAM information. For difficult cooling holes, elements with a gap sample or the optimisation of drilled holes, processes and strategies are sometimes developed in co-operation with the client.
A particular characteristic of CFK processing is 5-axis EDM-drilling utilizing 5-axis programming. The 5 axes are required to place the workpiece, because the electrode is simply capable of journey vertically.
Apart from particular person productions for the mould and die trade in addition to automotive trade, CFK additionally specialises within the fields of aviation and medical know-how. “We’ve got gained in depth know-how in programming and strategies, particularly for the turbine trade,” tells Christoph Over, managing director of CFK. The necessities fairly often end in frozen processes, which require a agency working process. “In large-part manufacturing, the whole lot have to be very correct,” explains Over. “The uncooked elements are very costly. Thus, it’s not potential to simply strive.”
(Supply: Heun Funkenerosion)
Huge processing spectrum
When the machine parks for EDM drilling needed to be expanded, the individuals accountable selected a Heun machine. Heun machines have beeen half and parcel of CFK’s manufacturing corridor since 1997. At current, CFK has one 3-axis Heun APos 600, one 3-axis Heun A-Pos 1200 and two 5-axis Heun A-Pos 1200s. A 3rd 5-axis machine will shortly be added.
With its Heun machines, CFK is ready to machine workpieces as much as a measurement of two,000 x 1,200 mm, a top of 800 mm and a weight of 8 t. The utmost journey is 1,200 x 600 x 800 mm (X/Y/Z). Electrode diameters from 0.1 to six mm can be utilized. Moreover, the machines are geared up with a 70-fold electrode changer to allow 24 h run instances. “We’re one of many few wage-based service suppliers to offer such machine sizes and such a large spectrum,” states Over.
For the reason that buy of the primary Heun machine, an in depth partnership has developed between the machine producer and CFK. Again then, the geographical proximity and the truth that Heun was one of the crucial skilled German producers of CNC machines within the subject of EDM drilling had been the principle causes for the acquisition, based on CFK. “Additionally, when five-axis know-how was launched, Heun was principally unrivalled,” explains Over. “Heun was one among solely two candidates and easily provided higher worth for cash.” Subsequently, they remained with the tried-and-tested machine producer.
(Supply: Heun Funkenerosion)
Confirmed machines and methods
CFK has remained very glad with the co-operation with Heun to today. Between the 2 corporations, there’s a vigorous trade of data. What’s extra, detailed and, above all, quick session is obtainable due to their geographical proximity. Christoph Over is aware of that “the standard is true and meets their wants”. It is usually essential that the staff have already gained expertise with the Heun machines and the associated management system and thus don’t have to be retrained.
Heun’s EDM drilling machines run with Peps, one of many main CAM methods within the subject of wire-cutting, primarily due to its straightforward operation and the potential for programming completely different conics, the corporate explains. The workers of CFK already know this technique. That’s the reason it is smart to solely buy new machines that run with Peps, just like the machines of Heun, CFK notes, explaining the acquisition.
One other benefit is the machining pace of Heun machines. “With a whole bunch of holes to be drilled, the pace have to be quick,” states Over. “Velocity and precision are the important thing elements in EDM drilling.” And never solely on this course of: Velocity additionally performs a significant function in start-hole drilling. “Begin-hole drilling is a essential evil and one typically needs to get it over with as rapidly as potential,” says Over.
Co-operation strengthens each side
To achieve success, one wants well-functioning know-how in addition to shut collaboration and lively trade between the machine producer and the operators. There’s an lively trade between the staff of CFK and Heun, the corporate explains. “For instance, earlier than the order of the brand new machine was positioned, two of our workers went to Heun to check it on some workpieces with a purpose to see whether or not the machine would meet our necessities or not,” Over says. If and when this isn’t the case, the businesses co-operate in fixing the actual drawback. Heun, in spite of everything, additionally grows with the necessities of its clients. Heun listens to the desires of the operators and thus they’re able to develop collectively.