Sodick Adds Functions to Cut EDM Wire Consumption

With the addition of the patented iGroove function, Sodick says it has quite literally put a new spin on the capabilities of wire EDMs. Featured in three of Sodick’s existing wire EDM lines (ALN, ALP, ALC), the addition of the iGroove and Stepcut functions reportedly show improved results in accuracy and surface quality while simultaneously reducing wire consumption — this machine lineup is especially suited for thick workpieces (60 mm or greater). With the cost of consumables on the rise, this model evolution also helps reduce the frequency of resupplying.

The iGroove function rotates the wire from the top to the bottom of the workpiece, ensuring the entire surface of the wire is used during the cut, and eliminating the need for taper compensation due to wire wear. This twisting mechanism creates a consistent, fresh electrode surface from the top of the workpiece to the bottom, Sodick notes, and, as a byproduct, the wire feed speed can also be slowed down. This leads to reduced wire usage without drawbacks such as excessive electrode damage — initial trials are said to have shown a 25% reduction in wire consumption on any given workpiece, with additional savings seen on cuts that require multiple skim cuts. Wire speeds are sourced from the built-in ALN conditions.

In tandem with the iGroove function is the support of step cutting, a process in which a workpiece of variable height is cut with a single program. This is possible due to Sodick’s “Thinking Circuit” which makes a 2D mesh as it runs its initial cut, memorizing the approximate thickness of the workpiece in each location. With this mesh of thicknesses, the machine is said to automatically optimize its cutting conditions as it runs skim cuts, simplifying the process.