Electrode software ‘triggers’ revolution at British toolmaker

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HASCO Hasenclever GmbH + Co KG

Ramada Acos

Vero Software Limited

Batch production proves to be ‘lights out’

“Until recently we only had one holder, but now we’ve created a dedicated jig comprising four new electrode chucks in specific datums on a hardened and ground steel plate,” Parsons said. This is now a permanent fixture on our Hardinge Bridgeport, and we can machine electrodes in batches of four by linking individual programs together – again fully utilising lights-out machining.” Parson further detailed how the data export from the software saves the company even more time and material. “Previously, where we had the same feature on a tool, but in multiple positions and different orientations, we had to make different electrodes of the same feature, but at different angles.”

He noted that the company can now fit one electrode into all the necessary positions as the software provides the X,Y,Z and U position so the same electrode can produce all the common features. “We just physically rotate it on the machine.”

Accuracy plays key role in program selection

The software is also said to give the company confidence that its electrodes will be 100% accurate: “We only get one chance to spark an electrode in position, so there’s no margin for error,” Parsons said. He noted that the program creates both the electrode and a co-ordinate sheet, a drawing report of the electrode and workpiece, X,Y,Z and U co-ordinates, and the start and finish points. This gives the EDM operator a visual picture of what he needs to achieve. “This is of paramount importance for accuracy.”

Parsons noted that while the combination of the Sodick spark eroder and Visi Electrode has already revolutionised the way the company designs and manufactures electrodes, it is absolutely key towards achieving their aim of doubling turnover over the next few months.

The company is expected to reach this objective with a step-by-step switch to other software from the Visi portfolio, including Visi Machining to replace the current CAM system. The shop’s moulds are already modelled, designed and analysed with Visi software. According to Parsons, “Part of the decision-making process was that eventually we would design and manufacture all of our tools within a single environment, including VISI-PEPS wire-for-wire EDM.”

Switching to Visi Machining is expected to reduce Alliance’s CNC programming time. The software’s templates contain tooling, tool path operations, feeds, speeds, depth of cut, etc., all of which can be stored and re-used on similar electrode families. Applying them to a new electrode is said to automatically create a new set of toolpaths using the same settings and company standards proven on previous jobs.

Parsons added that the shop has built up special know-how over the years and combined it with the latest machinery and CAD/CAM technology. “Vero are key to our production plans and will ensure we remain in a position to meet the demands of our clients faster than ever.”

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