Controlling sparks improves EDM wire life

Posted on 14 Feb 2020 and read 872 times
Controlling sparks improves EDM wire lifeA new EDM monitoring system has been introduced by Coventry-based GF Machining Solutions Ltd ( for its wire-cut EDM machines.

Spark Track prevents heavy wear from occurring at any point on the wire — extending its life and preventing breaks.

At the heart of this innovation is GF Machining Solutions’ generator technology, specifically its high-performance ISPS (Intelligent Spark Protection System) module; this accurately identifies the intensity and location of sparks along the wire and, when necessary, adjusts current and voltage rates to prevent concentration of wear on the wire.

The comprehensive and real-time spark distribution information that Spark Track provides to manufacturers enables them to “push their EDM machines to the limit”.

Martin Spencer, managing director of GF Machining Solutions UK, said: “The ISPS module eliminates wire breakage regardless of machining conditions and, as such, makes manufacturers’ wire EDM processes more reliable and secure.

“Spark Track solves problems such as wire oscillation, which can occur when machining different heights and tapered surfaces and can lead to wire breaks and damaged workpieces.

“Superior wire cutting performance is achieved when discharge distribution along the wire is as uniform as possible. Spark Track enables this to occur.

“ISPS and Spark Track work in combination to not only prevent wire breaks but also eliminate time-intensive resets and reduce the amount of time an operator has to devote to a given job.”

Other recent developments introduced by GF Machining solutions to better regulate the spark output of its machines include: the standardisation of high-performance generators across all of its EDM machines; and the re-design of its machines and the positioning of generators to place them as close to the wire as possible.

This makes the machines more responsive and able to react quickly to inputs from the control by reducing the distance computer signals and sparks need to travel.

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