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Manufacturer Meets Customer Demands With Sinker EDMs

Most just-in-time part requirements are typically associated with only high volume production manufacturers. For one mold and die shop, however, JIT has become a way of life to meet customer mold and die demands.

According to Rob Olsen, manufacturing manager at Model Die & Mold, Inc., Grand Rapids, MI, "What use to take us 16 - 18 weeks to produce a mold, now, at times, has turned around to the customer in just 12 - 14 weeks - or, in some cases, less."

Model Die & Mold is a large die and mold shop with a diversity of customers. They produce plastic injection and compression molds and dies for a number of world wide manufacturers in home and garden, medical, computer, military, automotive, and electronics markets. Annual sales are approximately 12 million.

MD&M’s customers demand molds with short turn-around times and sometimes with extremely complex shapes that are designed with many hard-to-produce thin, deep ribs.

Olsen said, "After we receive the CAD file to produce the mold from the customer, we carefully go over it to see if we can produce the part as it was rendered. We also see if we can make minor changes that will save production time, but will not affect the quality of the end part. We might find a rib doesn’t need to be squared off, saving EDM time. Or where possible, we can design the rib to be thicker - very deep and thin ribs are hard to fill in an injection mold. After the mold has finally been approved by the customer, we manufacture it the most economical way using CNC milling and EDM machines."EDM, EDM Solutions, Electrical Discharge Machine, Electrical Discharge Machinery, EDM Die, EDM Die Sinking, EDM Sinker, FOX Series, Tooling, Machine, Machining, Electrode, Graphite, Copper Tungsten, Parting Lines, Molds, Burning, Plastic, Injection, Molding, Plastic Injection, Plastic Injection Molding, Burning, Nontraditional Machining, Eroding, Spark, Generator, Discharge, Sinkers, Plungers, Sinker, Plunger, Power, Supply, Power Supply, CNC, Computer Numeric Control, Machine Tool, Stamping, Die, Dies, Die Making, Wire, Wire Machine, EDM Wire Machine, CNC Wire, Hole Popper, EDM Drill, Drill, 3 Dimensional Machining, 2 Dimensional Machining, Dielectric Oil, Poco, Carbon, Trode, Overcut, Arcing, DC Arcing, DC, Submerged, Autothread, C-Axis, C-Axes, Deionized, Deionized Water, Hydrocarbon, Chuck, Air Chuck, Electromagnetic, Magnetic Chuck, Precision, ACM, Abrasive, Abrasive Cutting, Abrasive Cutting Master, Altered, Altered Metal, Altered Metal Zone, AMZ, Ammeter, Amperage, A, Ampere, Angstofine, Anisotropic, Anode, Arc, Arc Guard, Arc Dampener, Arc Suppressor, Automatic, Automatic Tool, Automatic Tool Changer, ATC, Automatic Depth Finder, Average Current, Billet, Blind Hole, Breakthrough, Burn, Capacitor, Catalyst, Cathode, Center Flow, Center Flushing, Circuit, Coarse, Collet, Colloidal Suspension, Common Metals, Composite, Condenser, Condenser, Conductor, Contamination, Coolant, Copper Graphite, Core, Corner Wear, Crater, Cubic Inches Per Hour, Cut, Take a Cut, DC, Direct Current, Decalescent Point, Deionization, Depth Finder, Depth of Craters, Pits, Depth-to-Diameter Ratio, Diameter, Diametrical Sparking Distance, Dielectric Fluid, Dielectric Strength, Discharge, Discharge Channel, Discharge Dressing, Disintegrator, Dither, Downfeed, Dressing, Dual Power Supply, Ductile, Duty Cycle, Edge Finder, Efficiency, Electrical Discharge Grinding, EDG, Electrical Resistively, Electrode Growth, Electrode Management Technology, EMT, Electroforming, Electolyte, End Wear, Entrance Opening, Eroding, Exit Point, Exotics, Exudate, Farad, Filler, Filtering, Fine, Finish, Finish Cut, Flashpoint, Flexural Strength, Fluid Level Switch, Flush Pot, Flushing, Flushing Hole, Flushing Pressure, Frequency, Slurry, Solid State Power Supply, Sonotrode, Spark Erosion, Spark Gap, Spark Generator, Spark Intensity, Spindle, Split Electrode, Split Lead Power Supply, Square Wave, Stability, Staged Electrode, Stepped Electrode, Stroke, Subline, Suction Flushing, Superfine, Surface Finish, Surface Integrity, Surface Flushing, Surface Roughing, Swarf, Tap Buster, Tap, Taper, Tapping Attachment, Tellurium Copper, Temperature Cut-Off, Thermoelectric, Through-Hole Flushing, Tilting Head, Timed Retractor, Timer, Timing Unit, Total Form Machining, TFM, Tramming Attachment, Transducer, Transistor, Trepanning Electrode, Tubular Electrode, Tungsten, Ultrafine, Unstable, Vacuum Flushing, Vacuum Tube Power Supply, Vibrator, Viscosity, Voltmeter, Volumetric Wear, Wave Form, Wear, Wear Ratio, Wirecut, Working Gap Voltage, Workpiece, IM-9, EX 50, IM-20, ED-3, IM-25, EX-70, IM-6, EX-10, IM-9, EX-50, IM-20, ED-3, IM-25, EX-70, IM-6, EX-10, Super Alloy, Titanium, Beryllium Copper, Coolant, Cycle, Finisher, Ionization, Metal Removal, Metal Removal Rate, Microsecong, No Wear, Non Directional Finish, Off Time, On Time, Recast Layer, Rougher, Servo System, Square Wave Pulse, Work In Cubic Inches, Workpiece, Heidenhain, Heidenhain Control, Heidenhain CNC Control, O.S. Walker, Transor, System 3R, Erowa, Machining Center, Milling, Milling Machines, CNC Machining, Cutting Tools, Workholding, Workholding Devices, Vices, Clamps, Collets, Chucks, Fixtures, Tombstones, CAD, CAM, CIM, CNC, Computer Numerical Controls, Holemaking, Drilling, Drills, Drilling Machines, Multiple Spindle Drilling Machines, Grinding, Grinding Wheels, Superabrasives, Truing, Dressing, Turning, Turning Machines, Lathes, CNC Turning Machines, Saws, Saw Blades, Sawing, Metalcutting, Metalforming, Manufacturing, Contract Manufacturing, Job Shop, Measuring, Inspection, Coordinate Measuring Machine, Toolholding, Hirshmann

To meet demanding customer deadlines, Model Die and Mold replaced four older CNC EDM sinkers with three EDM Solutions Titan EDM Sinkers. Olsen said because of the Titan's speed and efficiency, the three could do the work of the previous four (they also just installed a fourth EDM Solutions Polaris machine).

"To find the right sinker, we looked at many different parameters: initial purchase price versus performance, style of machine, overall machine capabilities, tank size, and, most importantly, service and support. We had demos from just about every major manufacturer. Only two machines met our criteria. For performance, the two were just about equal. However, compared in cost, the nearest competitor's purchase price was nearly 50% more than the EDM Solutions Titan machines that we finally chose," Olsen remarked.

The three Titan EDM machines have tank sizes of 50 x 80 inches, which were about the same size as two of the four machines that EDM, EDM Solutions, Electrical Discharge Machine, Electrical Discharge Machinery, EDM Die, EDM Die Sinking, EDM Sinker, FOX Series, Tooling, Machine, Machining, Electrode, Graphite, Copper Tungsten, Parting Lines, Molds, Burning, Plastic, Injection, Molding, Plastic Injection, Plastic Injection Molding, Burning, Nontraditional Machining, Eroding, Spark, Generator, Discharge, Sinkers, Plungers, Sinker, Plunger, Power, Supply, Power Supply, CNC, Computer Numeric Control, Machine Tool, Stamping, Die, Dies, Die Making, Wire, Wire Machine, EDM Wire Machine, CNC Wire, Hole Popper, EDM Drill, Drill, 3 Dimensional Machining, 2 Dimensional Machining, Dielectric Oil, Poco, Carbon, Trode, Overcut, Arcing, DC Arcing, DC, Submerged, Autothread, C-Axis, C-Axes, Deionized, Deionized Water, Hydrocarbon, Chuck, Air Chuck, Electromagnetic, Magnetic Chuck, Precision, ACM, Abrasive, Abrasive Cutting, Abrasive Cutting Master, Altered, Altered Metal, Altered Metal Zone, AMZ, Ammeter, Amperage, A, Ampere, Angstofine, Anisotropic, Anode, Arc, Arc Guard, Arc Dampener, Arc Suppressor, Automatic, Automatic Tool, Automatic Tool Changer, ATC, Automatic Depth Finder, Average Current, Billet, Blind Hole, Breakthrough, Burn, Capacitor, Catalyst, Cathode, Center Flow, Center Flushing, Circuit, Coarse, Collet, Colloidal Suspension, Common Metals, Composite, Condenser, Condenser, Conductor, Contamination, Coolant, Copper Graphite, Core, Corner Wear, Crater, Cubic Inches Per Hour, Cut, Take a Cut, DC, Direct Current, Decalescent Point, Deionization, Depth Finder, Depth of Craters, Pits, Depth-to-Diameter Ratio, Diameter, Diametrical Sparking Distance, Dielectric Fluid, Dielectric Strength, Discharge, Discharge Channel, Discharge Dressing, Disintegrator, Dither, Downfeed, Dressing, Dual Power Supply, Ductile, Duty Cycle, Edge Finder, Efficiency, Electrical Discharge Grinding, EDG, Electrical Resistively, Electrode Growth, Electrode Management Technology, EMT, Electroforming, Electolyte, End Wear, Entrance Opening, Eroding, Exit Point, Exotics, Exudate, Farad, Filler, Filtering, Fine, Finish, Finish Cut, Flashpoint, Flexural Strength, Fluid Level Switch, Flush Pot, Flushing, Flushing Hole, Flushing Pressure, Frequency, Slurry, Solid State Power Supply, Sonotrode, Spark Erosion, Spark Gap, Spark Generator, Spark Intensity, Spindle, Split Electrode, Split Lead Power Supply, Square Wave, Stability, Staged Electrode, Stepped Electrode, Stroke, Subline, Suction Flushing, Superfine, Surface Finish, Surface Integrity, Surface Flushing, Surface Roughing, Swarf, Tap Buster, Tap, Taper, Tapping Attachment, Tellurium Copper, Temperature Cut-Off, Thermoelectric, Through-Hole Flushing, Tilting Head, Timed Retractor, Timer, Timing Unit, Total Form Machining, TFM, Tramming Attachment, Transducer, Transistor, Trepanning Electrode, Tubular Electrode, Tungsten, Ultrafine, Unstable, Vacuum Flushing, Vacuum Tube Power Supply, Vibrator, Viscosity, Voltmeter, Volumetric Wear, Wave Form, Wear, Wear Ratio, Wirecut, Working Gap Voltage, Workpiece, IM-9, EX 50, IM-20, ED-3, IM-25, EX-70, IM-6, EX-10, IM-9, EX-50, IM-20, ED-3, IM-25, EX-70, IM-6, EX-10, Super Alloy, Titanium, Beryllium Copper, Coolant, Cycle, Finisher, Ionization, Metal Removal, Metal Removal Rate, Microsecong, No Wear, Non Directional Finish, Off Time, On Time, Recast Layer, Rougher, Servo System, Square Wave Pulse, Work In Cubic Inches, Workpiece, Heidenhain, Heidenhain Control, Heidenhain CNC Control, O.S. Walker, Transor, System 3R, Erowa, Machining Center, Milling, Milling Machines, CNC Machining, Cutting Tools, Workholding, Workholding Devices, Vices, Clamps, Collets, Chucks, Fixtures, Tombstones, CAD, CAM, CIM, CNC, Computer Numerical Controls, Holemaking, Drilling, Drills, Drilling Machines, Multiple Spindle Drilling Machines, Grinding, Grinding Wheels, Superabrasives, Truing, Dressing, Turning, Turning Machines, Lathes, CNC Turning Machines, Saws, Saw Blades, Sawing, Metalcutting, Metalforming, Manufacturing, Contract Manufacturing, Job Shop, Measuring, Inspection, Coordinate Measuring Machine, Toolholding, Hirshmannwere replaced. However, the Titan models offer greater X, Y, and Z axis travel (when compared to other machines with similar tank sizes), giving them greater part size capability. This also helps the company to improve upon multiple part setups, increasing their overall "green light burn time." The Polaris has a smaller 40 x 60 inch tank size. On two of the Titan sinkers, a C-axis capability has been added.

The Titan machines are in operation 24 hours a day and usually five to six hours on Saturday. Some of the work is unattended where the operator sets up the machine for automatic cutting. However, Olsen said that "we tend to push the envelopes of all of our equipment, and I'd rather have an operator around just in case there are problems. Usually, one machinist can operate two machines."

Although 95% of their mold work is one-of-a-kind, and Olsen said its difficult to precisely quantify time savings over the older sinkers, he feels that the EDM Solutions machines provide roughly a 30 to 40 percent savings in total output.

Olsen said that there are a lot of reasons for these savings. Because the Titans and Polaris machines use the very latest EDM technology with precise CNC controls and power supplies, they are faster overall. Plus, because they get higher precision by using Heidenhain CNC controls, they can produce much better part surface finishing, saving time in benchworking. Olsen also likes the control's conversational and user-friendly nature.

Electrode usage has also been reduced. For example, instead of using an average of three electrodes on a typical burn, now one or two (depending on the mold) are used. A reduction on electrode usage saves CNC electrode machining costs. graphite cost and time spend at the EDM.

MD&M primarily uses P-20 steel with a Rockwell C hardness in the 28 - 38 range, as well as aluminum with inserted areas using Beryllium, Moldmax, Protherm and other materials.

EDM Solutions Titan sinkers have a maximum workpiece weight of 31,200 lbs., with a maximum ram capacity of 1,100 lbs., and X, Y, and Z axis travel of 52 x 28 x 18 inches. Polaris sinkers allow a maximum workpiece weight of 6,600 lbs., with a maximum ram capacity of 440 lbs., and X, Y, Z axis travel of 24 x 20 x 16 inches.

For more information, please consult these links (for more up to date information than is mentioned in the article):

©1998 EDM Solutions.
Last Modified: May, 1999