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Issue Winter 2009/2010
Issue Winter 2009/2010
www.sodick.org
www.sodick.org
Magazine for world leading manufacturers
More topics in this issue:
Page 2
Page 3
Page 4
New EDM range
HSC Milling
More than Entry Models
For even higher workpieces
Plastic injection molding
Original consumables
Multi-axis capability
The 5th generation of linear EDM:Sodick AG series are unveiled
at EMO 2009 in Milan...
Sodick’s new High Accuracy Linear HS650L 5 Axes Machining Center
combines High Dynamics and supreme Accuracy within a compact
Design...
By perfectly combining value and performance for its new entry
models Sodick has set a new standard for entry-level machines
including a new starter range...
Sodick‘s is offering world‘s first 8-axis simultaneous
control...
Sodick’s AQ750LH Premium enab-les even higher workpieces of up
to 600mm to be cut...
One of its main application markets is LED manufacturing,
dominating the market in Asia...
Sodick‘s original consumables are consumables you can
trust...
With manufacturing industry under increasing pressure
to demonstrate its ecological credentials and corporate
responsibilities, SODICK is leading the way by putting
positive environmental innovation at the heart of its
machine and business development programme.
No surprise then that an eco-friendly/green theme
will take centre stage at SODICK from now on. All
the new SODICK innovations are being optimised in
terms of physical footprint, machine tool components
and consumables, helping provide vital environmental
sustainability. So, in tandem with SODICK’s energy-
efficient power supply and low-energy advanced linear
motors, Sodick machine users can expect a healthy
reduction in their carbon footprint – something that
their customers, particularly those who are govern-
ment-funded, are increasingly looking for.
In addition to the underlying “eco” theme, SODICK
is promoting products into four key target markets:
firstly, high speed milling operations with state-of-the-
art linear 5-axis machines, secondly, large component
production, with SODICK’s “big beast” the AQ750LH,
thirdly, for established EDM users, the latest updates to
the existing SODICK AG range of wire and sink EDM
machines, and fourthly, bringing SODICK EDM tech-
nology to starter-level users with the brand new ippo1
sinker EDM machine.
For customers seeking serious milling solutions, the
SODICK HS650L is a compact 5-axis high speed ma-
chining centre incorporating a new 2-axis table de-
signed for both high accuracy and HSC machining.
Being compact ensures it not only requires less floor
space, it also helps reduce the use of energy and
consumables.
EDM users who need the capability to tackle really
large components will find what they are looking for
with SODICK’s linear drive AQ750L wire EDM.
Meanwhile, those customers looking for extra EDM
capacity will find the answer on the stand, with
SODICK’s latest AG600L wire and AG60L die sink
models. The AG600L features technical benefits that
include: automatic wire threading; and an upgraded
High-speed LP2WH controller. The AG60L die sink
model offers customers a host of advanced features
to provide up to 40% faster cutting speed and nano
wear.
All these advanced features not only confirm SODICK’s
world leadership in linear machine tool technology
applied to EDM and Milling, but also the company’s
mature attitude towards ecological responsibility
through environmentally sound manufacturing plants
and careful selection of machine components and
applied technologies.
Only one electrode can handle en-tire machining process from
roug-hing to finishing!The new “SGF2” Generator from Sodick
dramatically reduces electrode wear to le-vels not seen before,
less than 0.03%, ena-bling EDM Die sink users to achieve sharper
corners and cleaner edges.
In addition, electrode costs are reduced as fewer electrodes are
required for each job, usually only one is required, which also
reduces the chance of human error, particu-larly in setting up.
The SGF2 generator is available as standard on Sodick die sinker
EDM range.
SODICK Gives Advanced Technology the Green Light
World Innovation Nano Wear
Workpiece: NAK 80 (Steel)Cutting Depth: 15.5mmElectrode:
GraphiteCutting time: 1h 30minElectrode wear: 0.009mmSurface
finish: 1.5umRa
Electrode: Graphite (TTK9: TOYO TANSO)Workpiece: Steel
(SKD61)Depth: 10mmDielectric Fluid: VITOL-2Time: 30 mins (roughing:
19mins)
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AG400L & AG600LSodick now launches a new wire EDM AG series;
the
AG400L and AG600L.
The new models are developed to achieve even high-
er precision, easier operation, higher cutting perfor-
mance, higher stability and more “eco-friendly” than
the conventional models.
Creating a Bright and Prosperous Future by Offering Safe,
Reliable, Energy-Saving, and Eco-Friendly Technologies
Pursuit of the Highest Capability and Easiest Operation
By using the automatic three-sided rise and fall tank and the
4-side enclosed work-table, the large setup space is secure and
suitable for automation.
The dielectric level is adjusted automatically, eliminating the
need of manual adjustment in relation to workpiece thickness. The
machine’s X and Y axes have been exten-ded, while the machine’s
footprint remains the same.
Enhancement of Anti-Rust & Anti-Corrosive Properties
Sodick over the years has been leading the anti-corro-sion
technology in wire EDM with standard advanced generator circuits.
However, special applications and exotic materials may need further
specialised and ad-vanced technologies. Therefore, Sodick has
developed for this specific sector of the market, the ANCS (Anti
Corrosion System) technology. The ANCS prevents rust, corrosion,
and discoloration on workpieces while they are being machined or
left in the dielectric, which is available as an option. This
advanced Rust-Free system is the industry’s most advanced
anticorrosive function, effective for both steel and hard
metals.
Upgraded Performance on Complex Work-pieces
Workpieces with variations in height and pockets are always
challenging for wire EDM and over the years Sodick’s Thinking
Circuit has taken care of this. The new AG range has a standard
improved functionality with TC2 (Thinking Circuit 2). For
exceptional and ex-treme geometries the DSM (Dynamic Shape Master)
is an optional function to perform accurate and efficient wire-cut
EDM machining.
Advantages of DSM:
- Excellent cutting stability at extreme stepped portions,
pockets and through-holes
- Enhanced accuracy and surface finish
- Improved cutting speed
AG40L, AG60L & AG80L
With the introduction of the new AG sinker series: AG40L, AG60L
and AG80L, linear EDM technology has made another step forward.
With this 5th Generation of linear sink EDM, a new active
control system has been introduced, by simulta-neously performing
both discharge control and motion control through high-speed
communications. Sodick as a world leader in sink EDM, has extended
its leading technological position by the introduction of advanced
discharge circuits in its generator with circuits such as SVC
(uniform surface finish), SGF2 (nano wear) and many others.
Introducing the Most Advanced EDM Technology Offering Safe,
Reliable, Energy-Saving, and Eco-Friendly Technologies
Nano Wear
The SGF2 generator provides greatly improved machining speed, at
up to twice the previous rate with graphite electrodes and also
significant increases are obtained using copper electrodes. This
remarkable increase in speed is linked to significant reduction in
electrode wear to near negligible levels called “nano wear”.
Furthermore, the generator ensures the creation of a uniform
surface and also improves corner EDM performance in comparison with
the use of a con-ventional power supply.
Controlled tests with the SGF2 generator have provided
impressive results, including the deep machining of rib shapes with
virtually no wear on the electrode
(0.03%) achieving high precision, high speed machining which
would be impossible using milling opera-tions, similarly “nano
wear” machi-ning of sharp corner edges, turbine blades have also
been achieved. In real-life example cases machining times have been
reduced by as much as 40% at the same time as using a single
electrode in place of two electrodes.
Enhanced Operability
The new Sodick AG Sinker EDM range is designed for easy access
and operation. It has automatic three-sided rise and fall tank and
operation panels are positioned at
front of the machine, which makes possible an even larger open
space at the worktank. Dielectric filling and draining time is much
reduced for quicker machine set-up time. Thanks to its wide open
side, it is easy to install robot beside the machine and arrange an
automation system. Furthermore, the new ergonomic design the
positioning of the robot can be either side of the machine as
standard.
Compared with previous models, the new AG range has extended its
X and Y axes, and reduced the in-stallation space required.
The World’s First 10-Year PositioningAccuracy Guarantee
Conventional ball-screw driven machines lose much of their
original accuracy in about 3 to 5 years due to the wear and tear of
the ball-screw. To maintain the original accuracy, replacing of the
ball-screw is required which is a major cost. Customers today
demand higher-speed and higher-precision manufacturing, machines
are run-ning unattended 24/7 and this results in increased wear of
the ball-screw and therefore more frequent repairs.
Since 1999 Sodick machines have been driven by contact-free
linear-motor drives. Thanks to this main-tenance-free element,
Sodick machines are proven to retain their original accuracy for
over 10 years. This fact alone has meant that since 1999, Sodick
have been offering a 10-year machine positioning accura-cy warranty
for all of its linear motor EDM machines. Existing users and future
customers can operate Sodick machines with confidence knowing its
cutting-edge performance and accuracy will be assured.
Issue Winter 2009/2010
Issue Winter 2009/2010
www.sodick.org
www.sodick.org
Magazine for world leading manufacturers
New EDM range
The 5th Generation Linear EDMThe next generation of linear EDM:
Sodick AG series are unveiled at EMO 2009 in Milan
Machine Tool AG400L AG600LMax. workpiece dimensions (W x D x H)
600 x 470 x 240 mm 800 x 570 x 340 mm
Max. workpiece weight 500 kg 1000 kg
Work tank inner dimensions (W x D) 850 x 610 mm 1050 x 710
mm
X- / Y- / Z-axis travel 400 x 280 x 250 mm 600 x 380 x 350
mm
U- / V-axis travel 120 x 120 mm 120 x 120 mm
Taper angle (Work. thickness 100mm) ±25° (±45°: option) ±25°
(±45°: option)
Wire diameter 0.1~0.3 mm 0.1~0.3 mm
Max. wire speed Max. 420 mm/sec Max. 420 mm/sec
Distance from floor to table top 995 mm 995 mm
Machine tool installation space (W x D) 3200 x 3200 mm 3550 x
3700 mm
Machine tool weight 3800 kg 4950 kg
Total power input 3-phase 50/60 Hz 12 kVA 3-phase 50/60 Hz 12
kVA
Machine Tool AG40L AG60L AG80LWork table size (W x D) 600 x 400
mm 750 x 550 mm 1100 x 700 mm
Work tank inner dim. (W x D x H) 750 x 620 x 350 mm 950 x 740 x
450 mm 1400 x 950 x 500 mm
Work tank fluid level (Min. to Max.) 100 ~ 300 mm 150 ~ 400 mm
200 ~ 450 mm
Work tank capacity 190 Liter 330 Liter 690 Liter
X- / Y- / Z-axis stroke 400 x 300 x 270mm 600 x 420 x 370mm 850
x 520 x 420mm
Max. workpiece weight 550kg 1500kg 3000kg
Max. weight of electrode 50kg 50kg 100kg
Distance electrode and table top 150 ~ 420 mm 200 ~ 570 mm 250 ~
670 mm
Distance from floor to table top 830 mm 850 mm 840 mm
Machine tool dimensions (W x D x H) 1550 x 2440 x 2330 mm* 1852
x 2825 x 2570 mm* 2060 x 3100 x 2900 mm*
Machine tool weight 3900 kg* 5350kg* 8200kg*
Total power input 3-phase 50/60 Hz 10 kVA 3-phase 50/60 Hz 10
kVA 3-phase 50/60 Hz 20 kVA
* including dielectric tank
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Linear Milling Technology
5 More Reasons to Decide on Another Sodick Product
Issue Winter 2009/2010
Issue Winter 2009/2010
www.sodick.org
www.sodick.org
Magazine for world leading manufacturers
Simultaneous Cutting
Sodick Offers 8-axis Simultaneous Technology
EMO Milan is the Official Launch of Sodick’s new High Accuracy
Linear HS650L 5 Axes Machining Center. The HS650 5-Axes Linear
combines High Dynamics and supreme Accuracy within a com-pact
Design.
The Highlights of the HS650 5-Axes include: Sodick Linear Drive
Technology, an advanced LN5X CNC Con-trol System, a Super Rigid and
Dynamic 2-Axes Rotary Table and Liquid Cooled High Frequency
Spindle delive-ring 42,000 rpm, resulting in surface qualities
thought to be beyond the milling process.
Sodick has developed a Range of Linear High Speed Machining
Centers that not only impress with their Speed, but also with their
Market Leading Accuracy,
together with Sodick renowned reputation for Quality and
Reliability. The HS Machines occupy an enviable position at the
apex of the market.
The desirable combination of Speed and Accura-cy is achieved
utilising Dynamic Design, Sodick’s In-House developed and
manufactured Linear Motor Drive Technology controlled by advanced
CNC Cont-rols and K-SMC (Sodick Motion Control) developed
specifically for Linear Motor Drives. Based upon a compact and
extremely rigid Cast construction and using the highest possible
component parts, thus ensuring reliable and efficient operational
life.
Sodick has always developed their own controls and this has
allowed the company to develop, an 8-axis simultaneous control. No
other EDM manu-facturers are able to offer this feature. Multi axis
EDM machining is mainly used in the aerospace and medical
industries but also can be used part manufacture. The capability to
clamp the work-piece once and then execute complex operation
enhances productivity and accuracy.
New Challenges for the Turbine and Pump IndustriesThe production
of modern Turbines and Pump Rotors
are faced with immense challenges. The power of air-
craft and electricity turbines must increase, but the
emissions must be reduced. High performance pumps
in various industries must transport higher volumes,
but the gas or steam has become more and more ag-
gressive. Therefore specialists in material science have
developed highly resistant alloys. The result is that con-
ventional production cutting methods and processes are be-
coming unviable to create such parts. Electrical Discharge
Ma-
chining (EDM) is already an established key technology in
this field.
Sodick and JauchSchmider have created together new
avenues of opportunity. During the EMO 2009 Sodick will
present the new AG60L,
equipped with the New
Multiple-Erosion-Head
of JauchSchmider. This
combination has been
especially developed for
3-dimensional cavities.
The Perfect Synergy of
Sodick and JauchSchmi-
der; the JS Multi-Head
Innovation and Sodick’s
advanced EDM, multi-
axis linear control.
During the erosion process the Sodick multi-axis
control can rotate and control the movement of 7 Axes
simultaneously. Sodick and JauchSchmider have already
developed and installed this multiple-axis technology for
“Turn & Burn” at several European companies in aerospace
and medical industries for wire EDM as well as sinker EDM.
Next Development: 7-Axis „Turn & Burn“ Sinking EDMThe
channel geometries you see in the 3D pictures couldn’t
have been produced in the past. The electrode looks like a
corkscrew, twisting into the workpiece. This kind of channel
geometry is common in 5-Axis Milling applications, but only
for open channel form.
But now the channels can be produced as closed
channels with extreme Helix geometries. This kind of closed
channels forms reduce load on the blade walls and reduces
the wear on pump, rotor and seals.
In comparison to cutting tools the electrode costs are
negligible
particularly considering the nano wear of Sodick’s
generator.
They can be produced in almost all channel geometries and
sizes.
The EDM Process has already proven to be a more cost
effecti-
ve process in machining super alloys and much more efficient
milling.
...working togethermarket leaders...Sodick Europe Ltd tel: +44
(0) 2476 21 43 14 [email protected] www.sodick.org JauchSchmider
GmbH & Co. KG tel +49 (0)741/9297-0 [email protected]
www.jauchschmider.com
Sodick technology with 8-axis simultaneous capability
JauchSchmider multi-axis CNC rotary tables
SodickAeroPartnerAd 15/12/08 15:13 Page 1
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Issue Winter 2009/2010
Issue Winter 2009/2010
www.sodick.org
www.sodick.org
Magazine for world leading manufacturers
Not Only an Entry Model
AD325L and AD3L: Value and Performance Combined
New Starter-Level Sinker EDM
ippo1
Sodick offers the AD325L a wire EDM and the AD3L a sinker EDM as
entry models. Both models, regardless
of their entry prices, are equipped with linear motors and a
10-year accuracy guarantee as standard.
Both machines achieve the best accuracy and cutting speed as
other Sodick EDM models in the range.
Sodick has set a new standard for entry-level machines.
The AD325L offers the very best in high technolo-gy, precision
accuracy and long term durability and high standard specifi cation
reduces the need for op-tions. Standard features include a large
worktank with vertical access door, high performance LN1W generator
for optimum speed and surface fi nish. The result – a versatile,
high performance machinecapable of a wide variety of
applications.
The LN1W generator is now a standard feature of the AD325L,
working in conjunction with K-SMC, the very latest Sodick Motion
Control technology for linearmotors, to control axis motion and
continually monitor and correct the spark gap 500 times per
second.
The AD3L EDM sink machine from Sodick makesaccuracy, speed and
performance of linear motor drive machines such as the AG Series
models available to a far wider range of customers than has ever
beenpossible before. One of the key advantages of the AD3L is its
use of integrated high speed linear motors to maintain optimal
discharge frequency and so achieve maximum machining speed. The
Sodick linear motor provides high speed and high positioning
accuracy without backlash, while responsiveness, stability, and
performance are not diminished over time and remain
maintenance-free.
At the same time, the design of the machine, including its
optimized rib arrangement, signifi cantly increasesrigidity and so
provides an exceptional basis to deliver op-timum speed and
acceleration.
The AD3L features Sodick‘s latest „LN“ power supply unit,
increasing its capabilities for high-speed, high precision and
high-effi ciency machining. In addition, the machine is equipped
with „LN assist“, automatic programming function, SGF for nano wear
and theintegrated SVC circuit enables “no-polish” fi nishingfor
diffi cult “to-polish” forms, contributing to shorter processes and
improved quality.
Sodick Europe Ltd.Rowley Drive, BagintonCoventry, CV3 4LSUnited
Kingdom
Phone +44 (0) 2476 214 314Fax +44 (0) 2476 305 680E-Mail:
[email protected]: www.sodick.org SOD
E-M
AG-1
009-
UK-2
000
Where Bigger is Better
The Largest Wire EDM Ever: AQ750LHSodick’s AQ750LH premium
allows to cut even higher workpieces up to
600mm high. It features Sodick linear motors on X, Y, U and V
axes to ensure
smooth motion along all the axes together with 10-year accuracy
guarantee.
The U, V travel is slightly larger than X, Y travel (750 x
500mm) allowing very large angle to be cut at full height. The fi
xed table will support workpieces of 1050 x 750 x 600mm. Crane
loading is standard feature, making this the most user friendly and
polyvalent large wire EDM machine in the world.
The machine has the smallest footprint of machines of its class,
while providing an ultra-high-rigidity structure due to its unique
fi xed table design and the integrati-on of both electrical and
mechanical equipment in one unit. An optimum rib arrangement, based
on the la-test design technology, ensures that the machine that can
handle even very heavy work-pieces.
The AQ750LH also incorporates Intelligent Q3vic software,
allowing users to directly im-port 3D solid models with error free
data con-version, optimized CNC programming and redu-ced set up
procedure. In addition, the machine incorporates high accuracy
linear motors with Sodickmotion controllers on X, Y, U and V axis
and a „Ther-mal Multi Fit System“ capable of coping with large
temperature changes in the work environment without affecting the
accuracy of the machine.
The machine features a “V-line injection system”,
in order to minimise the defective fraction while
increasing productivity. This Sodick’s original and pa-
tented system demonstrates its capability especially in
precise mould manufacturing, e.g. side view LEDs with
thickness of less than 0.6mm which are used for mo-
bile phones or laptops. More than 80% of customers
in this market benefi t from Sodick‘s injection mol-
ding technology. The system also enables co-injection
(sandwich) moulding.
New at EMO 2009
High-Precision PlasticInjection MouldingIn EMO 2009, Sodick
introduces the plastic injection molding machine
“LD10c5”. One of its main application markets is LED
manufacturing,
dominating the market in Asia.
Customers throughout Europe are able to obtain genuine Sodick
EDM consumable parts, the quality of which has been fully tested
and assured inJapan, to obtain optimum productivity from Sodick
equipment. It is delivered from a location in end user’s
geogra-phic area, with full technical support through Sodick
Hightech Europe.
From its European base in the UK, Sodick conducts business
across Europe. Head-quartered in Coventry with an additional
facility in Dusseldorf Germany, Sodicksupplies spares and
consumables, and
service support to dealers and custo-mers all over Europe.
Currently, Sodick sup-plies their specialist and wellestablished
dealer network across Europe with the full range of origi-nal
Sodick consumables, including wire, pipe electrodes, wire guides,
pipe guides, fi lters, resin and KN and KS fl uids. The ability to
stock and ship from a European location has means that most items
can be deli-vered to a customer within 24 hours of receipt of
order.
Sodick’s Original Consumables
Consumables You Can Trust
As a market leader, Sodick has achieved excepti-
onal levels of precision and effi ciency through its
original technological development of products.
The company now introduces a brand-new starter
die-sinker EDM: the „ippo1“, being developed by
making the most of its in-house technologies and
know-how.
The machine is equipped with the „SVC“ circuit,
„SGF“ nano wear circuit and energy saving features
as standard. It will reduce electrode numbers, cut EDM
time and power consumption, which leads to much
cost reduction. The original LN Assist software helps
inexperienced operators to fi nd the optimised cutting
condition making use of Sodick‘s advanced database.
Thanks to these advanced and standard features, high-
quality and economical machine performance can ea-
sily be achieved.
The dielectric tank is placed underneath the machine
tool giving the smallest foot print in this category.
The machine will make a positive impact on mould and
part manufacture by bringing in Sodick‘s advanced
technologies to all workshops.
Specification AD325LX, Y, Z axis travel 320 x 250 x 220 mm
U, V axis travel 80 x 80 mm
Max. workpiece dims 700 x 570 x 215 mm
Max. workpiece weight 500 kg
Specification ippo1X, Y, Z axis travel 300 x 200 x 150mm
Worktank dimensions 600 x 454 x 260 mm
Max. workpiece weight 50 kg
Max. electrode weight 20 kg
Specification AD3LX, Y, Z axis travel 300 x 250 x 250mm
Worktank dimensions 925 x 555 x 300 mm
Max. workpiece weight 550 kg
Max. electrode weight 50 kg
