Mold builders can go seamlessly from CAD to CAM to machining with a stand-alone software programming module for sinker EDM. However, what’s groundbreaking is that it takes the guesswork out of determining part cavity burn parameters to optimize the EDM process and ensure the first parts are the right parts.

Using the special engineering software, shops can accurately determine the power settings for EDM generators by analyzing the actual geometry extracted from a 3D CAD part model. From this analysis, they can estimate machining time and then export a complete, optimized program directly to their sinker EDM, all while reducing machine programming time.

The kind of software uses CAD/CAM to provide the cavity or electrode surface areas to establish the optimal machine power settings. During operation, the sinker electrode moves into the intended cavity. As it cuts deeper, the machine’s power settings are adjusted based on the changing surface areas the electrode encounters.

In the past, operator experience was crucial. Now, there is no longer the need to interpret the active surface into a 2D projection. The software, based on patented surface evolution technology, slices the CAD/CAM part or cavity model into smaller more precise layers for optimizing depth-to-current settings during the sinker EDM process.

The ratio represents the power required at a specific depth and for the shape of the cavity at that depth. At the start of the burn, the cavity’s surface area is small, but as the electrode penetrates deeper into the cavity, the surface area increases.

How CAM for EDM Has Evolved

Before this advancement, existing software systems enabled adjustments for only a limited number of surface area layers of a cavity. As a result, shops often faced excessive electrode wear because the power settings were frequently too high for the small initial entry points of a cavity. By the time the electrode would reach full cavity depth, some of its features would already be worn. Shops would need to re-burn or clean up the cavity features affected by the worn electrode using a fresh electrode.

The sinker EDM programming systems had limited capabilities, mostly enabling users to set a general surface area sequence and make a few adjustments to the area being cut. To achieve greater accuracy in setting burn parameters, shops would have to slice the CAD model of the part cavity or the electrode into layers that represented the electrode’s progression into the cavity. They would then have to measure the surface areas of those layer depths to optimize the power settings needed for those individual surface areas. Not an easy thing to do

As software evolved, off-line programming systems transitioned into the actual machine’s human machine interface (HMI) and the HMI then became an off-line programming system. However, such a system only enabled a generic description of the cavity or the electrode, which wasn’t accurate enough in terms of surface area to truly optimize generator power settings like today’s CAM for sinker EDM.

In addition to its power-setting optimization capabilities, the software calculates how long it will take to burn a specific cavity, even for pre-milled cavities. The resulting time studies permits shops to make comparisons between time and electrode wear settings.

In doing so, they can determine the duration of a burn, regardless of the complexity of the electrode or cavity, by choosing generator settings that either reduce electrode wear or increase burning speeds. Faster speeds result in shorter burn times but require more electrodes. In contrast, slower speeds reduce electrode wear but lead to longer overall burn times.

What You Need to Know Now

To achieve optimal results with this type of software, shops must have a basic understanding of 3D CAD solid modeling and the ability to program and modify these solid models for calculating optimized power settings. For these reasons, this CAM includes a built-in solid modeler that imports a shop’s CAD model, which can be viewed and used to select the surface areas for the program being developed.

Also, shops need to know what type of burn to use, whether it’s a standard burn or surface finish burn. Because this CAM system knows the solid model of the cavity, it can recommend the most appropriate burn type. Shops simply click the system’s “education” tool that calculates everything for them. However, shops also have the option to select a burn type different from the system’s suggestion if they choose.

The software is installed on a separate computer rather than the machine to ensure sufficient memory capacity for handling large 3D CAD model files.

Determining the right power settings for sinker EDM generators has traditionally relied on operator experience and a bit of guesswork. Now, shops can simply input their part cavity or electrode 3D solid CAM model into this CAM software. The software will automatically calculate the appropriate power settings, creating an optimized machine program that ensures parts are produced correctly the first time.