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New Fast-Hole Drill EDM Features Fully Submerged Drilling with Processing Speeds Up to 10x Faster than Conventional Technology

For discharge machining of cooling air holes and shaped diffuser holes in blade and vane segments, Makino announces the new EDBV3 Fast Hole Drill EDM. The EDBV3 provides aerospace manufacturers with the speed, flexibility and reliability to effectively produce a wide range of hole shapes and sizes within a single setup, significantly reducing required tool variety and overall cycle times.

"The need for EDM drilling with advanced capabilities in blade and vane components has grown substantially due to new engine production requirements, as aerospace manufacturers strive to improve engine performance and reduce fuel consumption," said Brian Pfluger, Makino's EDM product line manager. "The EDBV3 fulfills these needs by building on Makino's proven EDM platforms with onboard filtration and resin systems and a user-friendly control system featuring preprogrammed hole profiles. Its 2-axis rotary table combined with automatic tool and guide change systems enable manufacturers to reliably machine complex features fully unattended, saving time and money, without risk to loss of part quality or accuracy."

The EDBV3 offers X-, Y- and Z-axis travels of 370mm, 270mm and 500mm (14.5 inches, 10.6 inches and 19.6 inches), respectively, and worktable dimensions of 250mm-by-270mm, with a maximum work piece weight load of 5kg (optional 15kg payload available). Its rotary C-Axis head features an EROWA compact chuck that enables automatic changing of electrode diameters down to 0.2mm (0.008"), and can spin up to 1000rpm.

All EDM drilling on the EDBV3 is performed fully submerged under water for higher part quality, improved stability and up to 10 times faster processing speeds than conventional technologies. To further improve productivity, the EDBV3 uses a single-electrode processing approach, which avoids the high cost of custom multi-electrode holders and standardizes the tool holders with a more flexible and cost-efficient system.

Fast and Reliable Tool and Guide Systems

For unattended burning of varying cooling hole diameters, the EDBV3 features automatic tool change (ATC) and automatic guide change (AGC) systems. A patented electrode set that combines the electrode holder and die guide together into a common assembly provides enhanced reliability with simple and precise automated exchanges. Together, these features enable 30-second ATC and AGC exchanges.

The EDBV3 uses a rigid guide-arm assembly to hold, locate and support the die guide, which can be alternately used as a programmable axis (W-axis). An integrated "middle-guide" system can be applied for small-diameter electrodes, preventing whipping, bending and vibration. Additionally, the middle-guide "fingers" automatically retract as the electrode tube reduces in size, using as much of the electrode length as possible.

The standard configuration of the EDBV3 includes a 24-station tool carousel system and 24 holder assemblies to fully tool up the machine. The tool carousel can be exchanged as a palletized magazine for extended hours of automated operation.

Unattended Software Monitoring

The EDBV3 employs several proven software technologies used in Makino's fine-hole sinker EDM machines. Makino's Model Plan system is integrated into the controller, providing user-friendly input screens with direct G- and M-code programming formats. An electrode length management system provides electrode wear tracking, and automatically exchanges electrodes when lengths become too short.

To prevent back-wall impingement during blade and vane cavity wall penetration, the EDBV3 includes a proprietary, highly sensitive breakthrough detection circuit. This sensing capability -- accomplished while delivering maximum speed and productivity -- uses a combination of different adaptive process-monitoring techniques. The machine's fully submerged processing delivers additional support by allowing debris flushing during breakthrough, for a faster and more stable process.

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Makino

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