The Engineering Technology Group (ETG), based in Wellesbourne, has introduced a new addition to its Gantry Eagle 500 series of die-sink EDM machines with the introduction of the next-generation Eagle G5 Precision from OPS Ingersoll which has built upon the workshop suitability of the Gantry Eagle 500 and combined it with the latest precision components to introduce a machine that delivers ‘groundbreaking’ precision and electrode usage even in graphite to VDI 8.

In developing the new Eagle G5, the goal was to create a machine to deliver the very highest in repeatable accuracy. Driven by the fact that accuracy requirements have almost doubled in the tool and mould-making industry, the challenges in terms of automation, material, wall thickness and precision will certainly fall into sharper focus in the future and the Eagle G5 now provides precise multi-cavity machining that was not available in this class of machine until now.

From a specification perspective, the Eagle G5 Precision has a 750 x 650mm table with work tank dimensions of 770 x 670 x 440mm and a dielectric level height of 450mm. Within this envelope, the new machine offers X, Y and Z travels of 525 x 400 x 450mm with a distance from the head to the table ranging from 135 to 585mm.

No other machine can offer this ‘useable volume’ within these movements allowing small and larger workpieces to be machined from one reference. Capable of workpiece loads of 1,000kg, the new machine provides sufficient space and capacity for any EDM processing requirements.

The G5 Precision also incorporates many new temperature stability features including the implementation of a full cabin around the working area and a new vacuum system for fume extraction.

It is equipped with the new Eagle Powerspark One control system and part of this control is the programming software Eagle Powerspark Editor (PSE). With this, OPS Ingersoll redefines user-friendliness with complex eroding tasks now created and adapted with ease.

By applying just a few simple steps, the number of inserts of each electrode and a wear compensation can be configured and realised in the electrode manager. Achieving low surface class and electrode wear combinations that have never been seen before with Graphite electrodes (also now featured in the G50).

OPS Ingersoll automation solutions offer a wide range of retrofittable solutions from 70 electrodes and 10 workpiece pallets (other variants possible), place coded or chipped (IMC LIGHT) through to multiple linked machines and workflow management.