Absolute Machine Tools has partnered with FANUC America to create an efficient automated cell used for producing custom-made plastic injection mold components. The machining cell is designed to address many shops' needs to produce multiple cavity and core components for the mold and die industry using graphite electrodes. The cell operates using electrode management, robotic part handling, advanced control intelligence and production machinery.
A Tongtai TMV-510G graphite machining center in the cell begins the process with a versatile FANUC M20iA robot. Then the robot loads the raw graphite workpiece into the milling machine for machining. The Donaldson Torit DFO-2-21.200 CFM dust collector automatically evacuates dust from the machine and the machining environment. Once that step is complete the robot takes the workpiece and places it into the vise of the wire EDM die sinker where the graphite electrode is burned into the final piece of metal that will be used to mold the plastic part. "Integrating automation with a FANUC robot is a smart, efficient and clean way to mass-produce graphite electrodes," said a company spokesperson.
The cell is a complete turn-key operation and was a focal point of Absolute's AccuteX booth at IMTS 2014. According to the company, this machine is engineered for high-speed, efficient production with a fixed column/moving table, 20,000 RPM direct drive spindle oil cooled for thermal stability and a 20 station high-speed arm-type automatic tool changer (ATC). This ATC produces tool changes in 0.8 seconds and chip-to-chip times of 1.9 seconds. With X, Y, Z travels of 20", 14.2" and 11.8" (500 mm, 355 mm, 295 mm) and a 23.6" x 13.6" (590 mm x 340 mm) work table area, the machine is designed to offer useful work volume in a compact 95" x 55" x 90" (2,375 mm x 1,375 mm x 2,250 mm) footprint that conserves shop floor space.
The AccuteX DS-550CM Die Sinker has an X, Y, Z working capacity that is 20" x 16" x 14" (500 mm x 400 mm x 355 mm). The work table size is 32" x 18" (813 mm x 457 mm). Maximum workpiece size is 47" x 27" x 17" (1,194 mm x 686 mm x 686 mm), and this machine can accommodate workpiece weights up to 2,970 lbs. (1,345 kg). AccuteX designed the EDM using finite element analysis (FEA) to ensure high accuracy machining. Further contributing to its rigidity is a heavily ribbed, high-grade Meehanite casting. Premium grade components such as precise drive system, linear bearings, class 5 pre-tensioned fine finish ballscrews and high resolution servo motors are used, along with roller type linear guideways and optical scales. Options for the DS-550 for greater flexibility include a built-in C axis with 360° indexing, an automatic electrode changer, dielectric cooler and custom tooling package. Users can perform 3-axis machining in six directions: multi-cavity, circular, square, any angle orbiting, internal/external spherical and 45° corner machining. The EDM can also do 3-axis linear machining, 2-axis arc machining, and it offers helical machining electrode compensation.
The FANUC M20iA robot is compact with a slim wrist and small footprint for operation in tight spaces. It can be mounted on the floor, wall or ceiling. It has a reach of 71" (1,811 mm) and full circular motion. Cabling, air tubes and valves are enclosed in the dustproof and waterproof robot arm. Vision and force sensors are available to tailor the robot to specific applications.
The final piece to the automation cell is a Donaldson Torit DFO 2-2 1,200 CFM dust collector that efficiently evacuates dust from the machine. Automatic shakers clean the filters and deposit the dust into a convenient-to-empty hopper.
This complete turn-key includes a Tongtai TMV-510G graphite machining center, AccuteX DS-550CM die sinker, FANUC M20iA/20M robot with R30iB controller, Hirschmann tooling package, safety fence 2 m high with man door and safety interlock wired directly back into the robot, end of arm tooling (EOAT) including gripper module, fingers, pneumatics package and sensors, robot riser, and all technical services including project management, design engineering, controls engineering, robot programming and installation set-up.
For more information contact:
Mark Cicchetti, EDM Technical Director
Absolute Machine Tools, Inc.
7420 Industrial Parkway
Lorain, OH 44053
513-701-5550
sales@absolutemachine.com
www.absolutemachine.com