What can be done when milling fails?
Production of parts which can not be milled anymore
Many parts can not be produced anymore using a chip making process. Fortunately, there are other production solutions which are not well known yet.
The Challenge
There are contours out in the field, which are very sensitive to machining. Long and thin parts, like microparts, don`t like side force from any cutting tool. They break very easy.
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The Solution
If the contours are symmetrical, wirecutting is the best and most accurate solution. If the workpieces are not symmetrical, sink EDM can be used to do most of the jobs with very high precision results. Both the Sinking and wire EDM processes do not produce any forces against the part.
To work cost effectively, it is useful to work with a single axis or multiple axis rotary table. A JS rotary table helps producing perfect workpieces. If the coordination of the set-up and programming of the machine is optimized, parts can be produced overnight.
The Example
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These photos show parts which can be produced over night. Perhaps in combination with an automation system, it can be a very profitable and competitive solution.
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