Machining of huge elements
Wire EDM catapults German producer into XXL machining




Supply: Press launch

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Small, delicate components will be processed with excessive precision on giant EDM machines, however not vice versa. What was already potential in EDM drilling, bes Funkenerosion from Fluorn-Winzeln additionally wished to understand in wire reducing.

Manufactured in a combination of drilling and wire EDM: An ejector with CO2 internal cooling at the top and a mould tool for brush production at the bottom.
Manufactured in a mixture of drilling and wire EDM: An ejector with CO2 inside cooling on the prime and a mould software for brush manufacturing on the backside.

(Supply: Ralf M. Haaßengier )

German producer bes Funkenerosion has needed to flip down orders up to now as a result of their wire-cut EDM machines didn’t have these journey distances. ”With our greater than 500 lively prospects, it is naturally troublesome when you possibly can’t settle for an order simply because the dimensions of the machines would not permit it”, explains Managing Director Markus Langenbacher.

And but the machine park geared up with Sodick EDM machines was already fairly spectacular with one ALC400G, one SLC400G, one AG400L and one AQ750LH. The wire reducing providers in contract manufacturing hardly left any buyer needs unfulfilled, solely within the XXL vary they needed to flip down orders every now and then.

“We used wire reducing proper from the beginning, and we quickly added die sinking as properly,” says Jörg Roming, who’s answerable for the wire erosion division. When contract orders began to extend, new EDMs needed to be bought. The selection fell on Sodick. “Sodick made us a gorgeous all-inclusive provide for 3 machines, which additionally satisfied us of their high quality and precision,” says Jörg Roming. Of the primary three machines, just one remains to be working; two have been changed over time. “We additionally tough a substantial amount of aluminium, which places numerous stress on the machines. At this time we all know that if we minimize aluminium on a machine all day, we have now to seize a cleansing rag every so often when the door is open and spend 5 minutes washing every part down, in any other case it’ll have an effect on the lifetime of the machine.”

XXL machining: Originally purchased as a replacement machine, now the perfect addition to be able to seamlessly continue wire-cutting large components from drilling machining.
XXL machining: Initially bought as a alternative machine, now the right addition to have the ability to seamlessly proceed wire-cutting giant elements from drilling machining.

(Supply: Ralf M. Haaßengier )

Broadly positioned as a contract producer in erosion

As a contract producer, bes Funkenerosion masters all erosion processes from EDM to drilling and wire erosion. Prospects additionally buy equipment and consumables comparable to drilling and threading electrodes in nearly all lengths and diameters instantly from the corporate in Fluorn-Winzeln. The primary prospects embrace software producers, mould makers, medical know-how firms in addition to the aerospace business. “Consumables are considered one of our main pillars, the inventory assortment is intensive, in order that we will all the time assure quick supply instances”, assures Markus Langenbacher.

The electrode materials is examined by way of efficiency by the trials division to ensure the shopper the very best outcomes throughout EDM drills; this strategy implies that even particular buyer requests current no downside for the corporate. Only recently a buyer ordered 20,000 electrodes from the corporate after profitable trials.

Succession settled

When the corporate founders determined to retire initially of 2021, a brand new managing director was wanted. In the summertime, Markus Langenbacher took over the administration of bes Funkenerosion. In fact, this was a stroke of luck, as a result of it isn’t all the time potential to discover a appropriate successor for a producing firm. It’s not unusual for international buyers who know neither erosion nor the shopper atmosphere to take over. After a couple of years, such firms are generally bought off once more in “particular person components” and are ruined. With Markus Langenbacher, nevertheless, a really skilled worker took over the helm. Having been with the corporate for 21 years, he not solely is aware of the enterprise and the processes out and in, but additionally the shoppers like nobody else.

Markus Langenbacher was properly conscious of the issues of his prospects: “The shoppers reacted by ready for the final two to a few years earlier than inserting orders. In spite of everything, they did not know what would occur to the corporate after the founders retired. Their reduction could possibly be felt when demand picked up once more.

The constellation is attention-grabbing as a result of the workers have identified one another for 20 years and now the previous colleague is all of a sudden the boss. Jörg Roming, who has been with the corporate for 18 years, sees this as a really constructive factor: “We discuss to one another way more frankly as a result of we have now identified one another for thus lengthy. That may be a great benefit. When issues come up, we will discuss with one another and discover options collectively.”

Finally, suppliers like Sodick additionally profit from the general constructive growth in EDM. After a smaller ALC400G was delivered to the corporate in Fluorn-Winzeln as a alternative machine initially of 2021, its giant counterpart, an ALC800GH, adopted in late summer season. “We now have taken step one in direction of additional increasing our wire EDM contract enterprise to XXL components with a considerably bigger wire EDM machine. This permits us to serve this market particularly and we not want to show down orders,” explains Managing Director Markus Langenbacher. New orders are to be generated by offering data to the broad buyer base. “With our machine park, we additionally attempt to particularly handle sure prospects that we have already got in EDM drilling. The client needs full machining of their XXL elements from a single supply, and we will now present that.”

Getting “larger” with wire EDM

For a few years, bes Funkenerosion has had a singular promoting level within the area of wire-cut EDM: with traverse paths of 1460 x 600 x 1,020 mm, elements weighing as much as 6 t will be drilled. The functions are additionally fairly difficult. In a current machining case, round 3,000 holes had been drilled on one part in 145 eroding hours. “We now have additionally dealt with elements with 14,000 bores — a one-and-a-half-metre-long pipe that simply barely match on our machine,” recollects the bes Managing Director. With an electrode changer, the machining then ran day and night time till the tube was fully perforated. “These are typical contract manufacturing orders for us. Nevertheless, our know-how in wire reducing goes again a lot additional. That is the place we began as a producing firm in 1983.”

Were able to ensure a perfect start with the first orders after the installation of the new Sodick machine: Markus Langenbacher, Managing Director of bes Funkenerosion and Daniel Günzel, Area Sales Manager BW of Sodick Germany.
Had been ready to make sure an ideal begin with the primary orders after the set up of the brand new Sodick machine: Markus Langenbacher, Managing Director of bes Funkenerosion and Daniel Günzel, Space Gross sales Supervisor BW of Sodick Germany.

(Supply: Ralf M. Haaßengier )

Initially, a Sodick VL600QH was to be bought as a alternative machine. However for the reason that ALC800GH was obtainable at quick discover, Markus Langenbacher and Jörg Roming took a take a look at it and finally determined in favour of it. “Additionally together with our used drilling EDM machines, the place we have already got the traverse paths, the ALC800GH matches completely to shut the circle between 800 mm begin gap drilling (most potential is 1,000 mm) and 800 mm wire EDM”, Jörg Roming can be happy with the brand new EDM machine on this respect.

It was a seamless transition: the outdated machine was dismantled, the flat-bed trailer with the XXL machine arrived, then the outdated machine was exchanged for the brand new one and transport prices had been saved accordingly. “We labored collectively optimally on each side,” confirms Jörg Roming. When the machine was within the corridor, he examined it with a granite angle calibrated to 2 my, with a size of 800 mm. Packed onto the machine in all instructions and examined, even the smallest machine and angle faults develop into seen. Since each Sodick machine undergoes a high quality check with generator calibration and geometry measurement earlier than supply, the granite angle confirmed no deviations, after all.

By the way, a job that was began with the outdated machine and now continued seamlessly on the brand new one: reducing peak 358 mm. “We seen the distinction in high quality instantly. One other huge benefit for us is that the management system is sort of similar, apart from a couple of enhancements. We carried on with the ALC800GH immediately,” recollects Jörg Roming. He was additionally in a position to switch the programmes to the brand new machine instantly. “We solely needed to make minor modifications to the postprocessor, in any other case the transition was fully seamless.”

For threading, the brand new EDM signifies a quantum leap, and the truth that the working directions are built-in in digital kind on the management system is a gigantic benefit, he says. Leafing by way of and looking out in person and programming manuals is not essential. Drawings, upkeep directions with illustrations, every part is listed merchandise by merchandise. Even half numbers will be discovered instantly through the search operate. “The temperature compensation of the ALC800GH naturally has an impact on precision, in order that even the XXL elements are eroded with excessive precision,” Jörg Roming is visibly happy.

New CAM options 3D

Our wire EDM machines run collection of as much as 500 items. “For us as EDM specialists, that may be a giant quantity,” Jörg Roming explains. The common for collection manufacturing is between two and 20 objects, however a big proportion constitutes of particular person components. The state of affairs is completely different with drilling, the place collection of 1,000 objects per week should not unusual. “These are largely coming from producers of precision instruments, for whom we use EDM to drill cooling channels as an prolonged workbench, for instance,” says Markus Langenbacher.

The client enquiries are obtained in numerous methods: one buyer sends the enquiry by e-mail and expects a citation, one other sends the part immediately in a package deal with a drawing, 3D information and supply date, a 3rd visits us in particular person. “Lots of the jobs are additionally repairs of instruments comparable to die punches, that are wanted yesterday if potential,” Markus Langenbacher says with a smile. And he has good purpose to chortle, as a result of his machine is so versatile that it will probably deal with most orders. Particularly within the case of wire reducing, the enquiries usually come by e-mail or by particular mail with the part and are mentioned with the shopper on the cellphone. The exemplary prospects ship an information set that’s 100% labored out and dependable. For the final 30 years, one worker was accountable just for the CAM programming of the wire-cutting machines, however she retired initially of 2021. The corporate has due to this fact changed the CAM system for wire-cutting together with the brand new Sodick machines. For the reason that outdated CAM is just not being up to date and may solely show 2D, it’s to be step by step changed by the brand new CAM. Jörg Roming now runs the CAM utilizing the 3D information provided by the shoppers after which already will get fairly good simulation parameters as to which sides must be machined and the way. “The complete commissioning course of together with post-processors went like clockwork with the brand new CAM,” the EDM skilled is solely thrilled.

Give attention to upkeep and customer support

Though a free phone hotline is obtainable with each newly delivered machine for your complete lifetime of the machine, Jörg Roming has hardly used it to this point. “Our hotline is way more direct right here,” he says with an amused smile directed at Daniel Günzel. “If you happen to preserve your machines properly, you nearly by no means must dial the hotline.”

As a result of design of the sink with out painted components, solely chrome steel and full ceramics, in addition to the clever head design, upkeep and cleansing are simply performed in a couple of minutes. When the machine has been working all day and has had workload, it’s often adequate to spray the sink and heads with the water gun provided. Nonetheless, the workforce at bes Funkenerosion takes upkeep significantly. Markus Langenbacher explains: “We now have just lately drawn up a guidelines that’s particularly tailor-made to every machine by way of cleansing and upkeep. Jörg Roming provides: “This can be very necessary to me that my EDM machines run reliably. If we do an intensive upkeep yearly, that goes a great distance and I’m assured that once I wish to begin a job on a machine, I can begin instantly and with out bother.”

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