CDM Tool & Manufacturing Co., Inc., Hartford, WI, builds precision molds for the plastics industry. Recently, CDM replaced a large capacity Ingersoll 1300 gantry EDM with the same style and size machine, with one exception: the new EDM has a Mitsubishi Multipulse CNC control." The size of the original machine worked well, and we liked the high quality of the Ingersoll's bridge-type design that offers the rigidity needed for large workpieces," explained Brian Priestaf, vice president and general manager.

The increased capacity and capability of the new power supply has made the purchase a big success, producing significant increases in speed and a dramatic improvement in rib burning. "The larger power supply has made all the difference in the world," Brian said.

CDM's other EDM machines are Mitsubishis, with AC drives and 32-bit Fuzzy Logic controls that are compatible with the Mitsubishi Multipulse CNC control on the new Ingersoll EDM. Priestaf said he invested in the new Ingersoll partially to achieve compatibility and continuity, like the ability to run the same program on a different machine and to inter-change electrodes from one machine to another. The control screens are identical between the Mitsubishi and the new Ingersoll EDMs and they both accept the same 3R tooling.

Some jobs, such as the deck for a garden tractor, require the full capacity of the large tank on the Ingersoll 1300. CDM frequently EDMs molds weighing up to 20,000 lbs., Brian said. For those jobs the ease of loading the bridge-type Ingersoll is a big plus.

Just as often, however, the Ingersoll is set up with two smaller jobs, a quick-burning one in front, and a long-term job in the rear. Faster turn-around jobs are run when operators Bill Wetzel, first shift, or Harold Langenecker, second shift, are present. The long burns are reserved to run overnight for untended operation. "Our goal is efficiency," Brian said, noting the tight turn-around times required in moldmaking today.

Bill said that he appreciates the increased speed of the new machine. "The old one was a dinosaur compared to this one."

Both Bill and Harold are experienced operators who could deal with the differences in programming between the old Ingersoll and the Mitsubishis, but "even for experienced operators it is enough to think about EDMing, without having to constantly think about the differences in programming the machines," Brian added.

Operator-friendly controls are particularly important when training new operators, Brian said. He is active in promoting technical education, and CDM operates a full apprentice-ship program. CDM employs both toolmakers and machinists. All have learned programming, a function that has been moved out of the office and is now performed by the machine operators.

The new Ingersoll 1300 EDM fits in well with CDM's goals of working efficiently to accomplish a greater amount of work with the same time and effort.