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GF Machining Solutions’ Spark Track technology for wire-cutting EDMs, powered by the company’s Intelligent Spark Protection System (ISPS) module, prevents wire breakage that occurs when cutting irregularly shaped workpiece features. With Spark Track technology and the ISPS module, wire EDM users gain secure and uninterrupted EDM processing, improved machining efficiency and ease of use for operators, the company says.

Spark Track constantly monitors the spark distribution along the EDM wire. Based on the spark data gathered, the ISPS analyzes and automatically recognizes shape changes, adapting machining parameters accordingly to prevent wire breakage during roughing. As a result, irregular shapes such as cavities, varying heights, taper surfaces and sharp corners can be more easily roughed without the need for operator intervention to set up machining conditions in advance, the company says. The resulting reliability allows for full automation. 

Angled part surfaces represent an example of where Spark Track and the ISPS module bring high efficiency to the wire EDM process, according to the company. Such tapered surfaces can create non-homogenous flushing conditions at a wire EDM’s upper nozzle, disrupting the machining process. The ISPS module is said to eliminate the need for the machine operator to adjust the process to accommodate such difficult machining conditions since it analyzes the spark distribution data, automatically recognizes the shape change and adjusts the process to increase machining efficiency.