GF Machining Solutions (GFMS), an EDM, three- and five-axis milling and laser machine tool specialist and advanced automation systems solutions provider, has recently introduced four new innovative features to its latest, ‘next generation’ wire EDM machines.

The new innovations include: Intelligent Spark Protection System (ISPS), iWire, Unique and TurboTech, to deliver increased flexibility, speed, accuracy, performance and efficiency — they also help customers achieve more for less and have a favourable environmental footprint owing to reduced wire consumption.

The Spark Track platform that monitors spark distribution along the wire and that was launched by GF Machining Solutions in 2019, has already proven itself to be a game-changer in wire-cutting EDM. With the Intelligent Spark Protection System (ISPS) module, which is an integral part of Spark Track technology, the EDM process is simplified and made easier.

With the new ISPS module, sparks are analysed and their concentration is clearly defined. As a consequence the parameters of the machine are able to be adjusted accordingly (in real time) to prevent wire breakage and maintain an optimised cutting speed. The process is automatic and effective, especially when difficult cutting conditions are being experienced, and as a consequence machine downtime and process interruptions are eliminated.

Optimises wire spool unwinding speeds
Meanwhile, iWire is a sustainable, intelligent process that helps optimise and reduce wire consumption. As an adaptive software module based on the Spark Track platform, iWire comes into its own when individual workpieces to be machined present big variations in height or when the upper and lower heads cannot be placed close to the surface of the workpiece. It adjusts and optimises wire spool unwinding speeds by accurately estimating (in real time) wire wear according to cutting conditions. The module help reduce wire consumption rates (by up to 40%) and wire expenditure costs.

Uniqua is the new HMI for EDM machines. It helps customers improve their productivity, determine and re-order their machining priorities and ultimately get the most from their wire EDM machines. It has been designed and built for the customer and adapts to their way of working. Integrated onboard help and tutorials are available, making it intuitive and easy-to-use not only for operators accustomed to ISO programming and for seasoned users, but also for relative novices too.

Finally, TurboTech, a new ‘state of the art’ technology that is faster than the existing speed technology on wire-cutting EDM machines, is fully compatible with the Spark Track platform. It offers an excellent speed-accuracy compromise in good or bad flushing conditions, is available for all wire types (brass, speed and quality) and is fully integrated in Uniqua or AC Cut 2 interfaces. It delivers faster machining times and lower wire consumption.

GFMS says its ISPS, iWire, TurboTech and Uniqua, on its next-generation wire-cutting EDM machines, provide customers with flexibility, productivity, efficiencies and unrivalled performance that set new benchmarks in the industry.