Kenilworth-based Walter Ewag UK Ltd (www.walter-machines.com), which is part of the United Grinding Group, recently released its Diamond Plus package.

Based on the development of new software, an advanced GIF (generator inter-face) card in the machine generator, as well as a new flexible electrode, the package is designed to boost PCD-tool production on its Walter Helitronic Power Diamond machines (it can be retrofitted to Helitronic Power Diamonds with a Fanuc CNC).

In addition to cutting production times by as much as 40%, Diamond Plus improves cutting edge quality (edge chipping down to just 5µm at 10µm grain size) and shortens the time required to program complex PCD forms.

The GIF card — the ‘brain’ of the generator — includes a new variable acceleration factor that automatically monitors and controls process variation to optimise the erosion environment independently of issues such as differences in materials, electrode shape, stock removal and tool profile.

In addition, operator efficiency is further improved with the revised WWM P52 PCD profile tools/user interface software suite.

The user-friendliness of this software has been enhanced and savings on programming times are achieve by, for example, a new routine for automatic electrode dressing, the input of default values, touch screen navigation and a variety of short-cut buttons.

The first user in the world of Diamond Plus is Technicut, a Sheffield-based tooling specialist that collaborated closely with Walter Ewag UK and Walter Maschinenbau GmbH over the past two years to help develop Diamond Plus.

Technicut’s Dan McConaghie says: “Nobody can envisage what the world market for PCD tooling will be, but it is certain to grow as the use of carbon fibre and carbon-aluminium ‘stacks’ increases.

“We need to ensure we are at the forefront of this type of tool production. A main benefit of the Helitronic Power Diamond is its ability to produce both carbide and PCD tooling on the one machine, and to change easily and quickly between the two routines.”