Overview

This document provides detailed technical specifications, features, and performance data for CHMER's Linear Motor Drive Series of Die Sinker EDM machines, including models D322L, D322ZL, D322CL, D323CL, D433CL, and D6050CL. It highlights the machines' advanced linear motor technology, mechanical design, and control systems aimed at improving machining speed, precision, and surface finish quality.

Machine Specifications

• Work Table and Tank Sizes: Work tables range from 500x350 mm to 800x600 mm. Work tank dimensions vary accordingly, with heights between 190 mm and 580 mm depending on the model.
• Axis Travel: X and Y axis travels range from 300x200 mm to 600x500 mm; Z axis travel varies from 250 mm up to dual Z axes with 250 mm and 300 mm travel.
• Drive Systems: X, Y, and Z axes are driven by combinations of handwheels, AC servo motors, and linear motors depending on the model, with the latest models featuring linear motors on multiple axes for enhanced speed and precision.
• Weight and Dimensions: Machine weights range from 1000 kg to 2800 kg, with outside dimensions scaling from approximately 1300x1300x2150 mm to 1700x2550x2500 mm.
• Pneumatic Requirements: All models require 6 kgf/cm² pneumatic pressure for dielectric tank operation.

Electrical and Performance Parameters

• Max Machining Current: Ranges from 50A to 150A depending on power supply unit.
• Power Input: Between 4 KVA and 10 KVA.
• Electrode Wear Rate: Approximately 0.2% across models.
• Surface Roughness: Best surface finish achievable is around 0.25 µm Ra.

Dielectric and Filtration System

• Dielectric tanks use paper filters with capacities from 280L to 900L, equipped with built-in oil pumps of 0.5 HP.
• Dimensions and weights of filtration units vary by model, supporting efficient dielectric fluid management.

Mechanical and Structural Features

• New bridge-style design with linear motor drives on two moving rams and a stationary work table allows rapid positioning and supports a wide range of applications from small precise parts to mid-large jobs.
• Linear motors integrated with high precision LM guideways on X, Y, and Z axes increase positioning and machining speeds.
• Z axis is balanced by an adjustable pneumatic cylinder to optimize electrode load.
• Use of aerospace-grade lightweight materials for Z axis reduces motor load and enhances cooling and acceleration/deceleration performance.
• Large section area design for Z2 axis with AC servo motors supports large electrode use.

Linear Motor Drive System Advantages

• High machining speed and response with low friction and minimal positioning lag compared to traditional ball screw drives.
• Improved surface finish consistency and reduced electrode wear, especially in deep rib burns and poor flush conditions.
• Enhanced traverse speed and positioning accuracy.
• Vacuum suction system effectively removes chips to maintain consistent spark gap and reduce secondary discharges.

Control System and Functional Interface

• Fully conversational ZNC or CNC controls enable quick selection of cutting technology based on electrode and workpiece materials and desired surface finish.
• Automatic selection of optimal rough, semi-finish, and final finish cutting parameters from a built-in library, with options for user modification and storage.
• Pre-programmed "E codes" for standard machining functions and full programmability with standard "G" and "M" codes.
• Display window for real-time monitoring of discharge status.

Cutting Technology and Circuit Features

• Medium-low current impulse control to reduce electrode wear by managing current ascend speed.
• Rapid energy circuit reduces OFF time to increase machining speed without significantly increasing electrode wear.
• Special capacitor technology minimizes electrical noise and surge, enhancing EDM response during high current discharges.
• Micro spark finish circuit improves discharge current for mirror-like surface finishes.
• Pre-programmed "S" codes handle a variety of electrode and workpiece materials.

Performance Test Results

• Consistent machining measurements with minimal variation (e.g., measurements around 2.696-2.698 mm).
• Surface roughness values consistently around 4.2-4.9 µm Ry.
• Linear motor systems demonstrate significantly higher traverse speeds (18-21 m/min) with no positioning lag compared to ball screw drives (2-5 m/min with lag).
• Electrode consumption reduced by approximately 25-27% and processing time decreased by up to 35% when using linear motor drives versus AC servo motors.
• Improved surface roughness and machining speed confirmed through comparative tests.

Electrode and Workpiece Examples

• Electrode materials include graphite (SC50C) and copper (SC45C) with sizes such as 0.82x5.0 mm and φ9.95 mm.
• Machining depths range from 1 mm to 2.7 mm with low current settings (e.g., 6A to 30A) for precision finishing.
• Example machining time for a 2.7 mm depth on NAK80 workpiece is approximately 13 hours with a surface roughness of 4.5 µm Ry.

Summary

CHMER's Linear Motor Drive Series EDM machines combine advanced linear motor technology, precision mechanical design, and intelligent CNC controls to deliver high-speed, high-precision machining with reduced electrode wear and superior surface finishes. The integration of vacuum chip removal, specialized discharge circuits, and user-friendly programming enhances productivity and machining quality across a broad range of applications.