Cimatron: Automation of Electrode Design and Manufacturing Including the EDM Process

Electrode Design – Templates Do Much of the Routine Work for You 

For electrode design, Cimatron offers a dedicated module with functions that make the designer's work significantly easier. One of the main aids is the ability to use templates while retaining the option to modify the functions used afterwards. Although using templates can be problematic for electrodes with complex geometries, a template is beneficial even in these cases. Often, the designer only needs to adjust the template or steer a specific function in the right direction.  

EDM Setup – Automatic Operation and Avoiding Errors 

In Cimatron's CAD environment, the designer adds instructions and information for the die-sinking process immediately after completing the electrode. A special EDM Setup profile was developed in collaboration with Penta for its PENTA CNC die-sinking EDM machines, enabling NC code to be generated directly from Cimatron. This code includes not only die-sinking data, but also approach paths, retract moves to a safe plane for moving the electrode to the next die-sinking location, and calls to additional macros that can perform a wide range of tasks, from sending an informational SMS upon program completion to draining the machine tank. 

Electrode design in Cimatron CAD/CAM

The aim of preparing the die-sinking process within the CAD solution is unattended operation of the die-sinking machine: at the end of the shift, the machine operator loads the electrodes into the magazine according to the supporting data and, after locating the workpiece, uploads and starts the program. The die-sinking machine performs die sinking automatically according to the program.  
With Dexios software, it is possible, for example, to import electrode offset data from a CMM machine. The advantage of this approach is that manual entry of the electrode position is completely eliminated, preventing the operator from making errors such as entering an incorrect decimal place. 

Electrode Machining – NC Programming Using a Template

The electrode machining process follows seamlessly from the design, primarily thanks to the data entered by the designer. The data is transferred to the machining environment and automatically inserted into the procedures. The NC programmer therefore does not need to enter the undersize manually, eliminating another point at which human error can occur. If several types of electrodes need to be produced, it is sufficient to program one and then duplicate the entire program with a change to the electrode type setting. This again saves the programmer time. Cimatron also allows NC procedure templates to be inserted, either individually, one after another, or as a prepared sequence from roughing through finishing and cleanup. Thanks to the interconnected process, it is possible to reach a point where the templates machine the electrode without further intervention by the programmer.

Production Management – Dexios Automation Software 

Dexios Lite serves as the backbone system for managing and optimising the die-sinking process, working closely with Cimatron CAD/CAM software and the die-sinking machine from PENTA EDM. Dexios imports the data from the EDM Setup function in Cimatron. Once imported, further information can be added or loaded, such as electrode offsets from a CMM machine or the assignment of an electrode holder. This ensures complete project preparation before die sinking itself. 

Assigning an electrode holder using an RFID chip

During the die-sinking process, Dexios controls the automated operation of the die-sinking machine, including electrode changes. It enables the simultaneous machining of multiple identical parts or different parts on a single machine, increasing production efficiency. The die-sinking machine operator focuses only on preparation, such as clamping parts and loading electrodes into the robot magazines or the machine magazine if no robot is installed, without having to manually enter approach information or undersizes. Once the machine is switched to automatic mode, Dexios takes full control of the process.  

Measurement on a CMM, Milling Machine and EDM Machine 

Depending on the CMM machine used, the loading and measurement process can be automated. As a first step, an interface can be created between the CMM machine and Dexios to transfer the measured offset data. 

Alternatively, an interface can also be created between Cimatron and the CMM machine. This can open up the possibility of programming the measurement process in Cimatron.

Cimatron can also be used to program a measurement process that takes place directly on the PENTA EDM machine. This measurement can be used to verify the positioning of the part in the machine or to set the user coordinate system. Points can also be measured and the results exported back to Cimatron, where they can be visually checked and exported to a report. 

Automation of Electrode Production and Die Sinking at Peartec s.r.o. 

The toolmaking company Peartec s.r.o. has been using Cimatron CAD/CAM since 2020 for electrode design and milling and mould milling, and is gradually transitioning to it for mould design as well.

Automated EDM workstation at Peartec

A pilot installation of the solution described above took place here during 2024. 

1. Cimatron generates fully prepared data for die sinking.  

2. At Peartec, software from Dexios now controls every step of the die-sinking process. It sends data to the die-sinking machines and controls program execution, while also being able, if necessary, to load electrode offset data based on measurements previously performed on a CMM machine.

3. Electrode changes are handled by a robotic arm also supplied by Penta, enabling fully unattended operation.