ASC uses digital signal processors and field programmable gate arrays on the generator itself. The EDGerosion generator is able to monitor and process everyspark, in real-time. The waveform of each spark is automatically monitored and categorized based on the material being eroded, erosion gap distance, and other factorsessential to the optimal erosion process. The generatorcan then dynamically adapt the energy level of each-and-every spark (current, voltage, duration, and time-off) tosuit the material being eroded.
ASC optimizes the erosion process leading to lesscobalt leaching and a reduction in undercut at thePCD-carbide border. This leads to a stronger cuttingedge and a finished tool that is less prone to chipping,and helps achieve longer tool life, less tool wear, andlower tooling costs. Testing on tooling suited to the machining of carbon fiber reinforced plastic showed a toollife increase of up to 100%.
Boost Power Electronics With ANCA Mo-
tion SparX Erosion Generator
ANCA leaned on the expertise from their sister company, ANCA Motion, to optimize the electronics to enable even higher and more aggressive erosion all the whilemaintaining very high surface finish results. When compared to equivalent componentry, the “mega-amp perpulse” technology enables ANCA customers to broadenthe power range they can access and utilize. The ANCAMotion SparX Erosion Generator exhibits superior performance over the range of extra-heavy roughing to ultra-fine finishing operations, utilizing pico-pulse technology for high energy-density ablation. This enables vastlysuperior controllability, providing customers with optimized feed rates, superior surface quality, and drasticallyreduced cycle times. This pulse precision allows erosionthat ranges from ultra-low energy pulses for exceptionalultra-fine finishing, through to high energy pulses for fastmaterial removal.
In the PCD erosion process, cycle time is directly re-
lated to the MRR. The ANCA Motion SparX Erosion
Generator delivers unrivaled increases in MRR utilizing
the new extra-heavy roughing, super fine finishing,
and ultra-fine finishing operations. What this equates
to is an unsurpassed increase in MRR and a 50%
decrease in cycle time compared to competitor ma-
chines—arguably the fastest cycle times in the market.
Additionally, erosion surface quality also sees an im-
provement across all power modes. Polished surface
finishes of Ra < 0.1μm and Rz < 0.5μm can be easily
achieved using the ultra-fine finishing process with
pico-pulse technology. These operations enable the
production of superior cutting edges necessary for the
most demanding of cutting tool applications.
Combining intelligence in a domain once dominated by brute force electronics not only gives ANCAcustomers an edge over the competition, but enablesa smarter approach to tool making. The differencebetween our approach and the approach of our competitors is that ANCA focuses on what our customers want to achieve with their erosion process. Theystrongly told us that they wanted a process optimizedfor helical and round PCD tooling. We worked closelywith ANCA Motion to design our erosion generatorto suit not only shear tooling but the infinite arrayof highly complex geometries, rather than reusinggenerator technology originally created for wire electro discharge machining (Wire-EDM). Our approachturned the industry on its head. We let the geometriesdictate the process, not the process dictate the geometries available.
We used intelligence to outperform brute force, like thefox outsmarting the hare.
ANCA is a market-leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters.ANCA has offices in the UK, Germany, China, Thailand,India, Japan, Brazil, and the USA as well as a comprehensive network of representatives and agents worldwide.
ANCA CNC grinders are used for manufacturing precisioncutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics, and medical.
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