Sodick AL1000G

The AL1000G's linear motor Z-axis with 1.2G acceleration enables electrode jump cycles fast enough to create a pumping action in the spark gap that clears EDM debris without external flushing. At 36,000 mm/min Z feed rates, the electrode oscillation displaces dielectric rapidly enough that debris is expelled before it can cause secondary discharge damage. This works best on open cavity geometries with good dielectric access from above. Very deep, narrow ribs (depth-to-width ratio above 10:1) and sealed blind pockets may still require supplemental flushing.

The AL1000G's 200-700 mm electrode-to-table clearance range accommodates electrode extensions, large electrode holders, and tall electrode assemblies. Maximum electrode weight depends on the electrode chuck capacity specified — standard configurations handle graphite electrodes up to approximately 100 kg. For very large graphite or copper electrodes used in automotive die cavities, consult Sodick about the appropriate chuck and extension system. The ATC option is particularly valuable on the AL1000G to enable multi-electrode burns without manual intervention across shift boundaries.

With the standard TMM3 generator and graphite electrodes, the AL1000G achieves VDI 12 (Ra 0.40 um) routinely on steel. The e-pack fine-pulse option extends this to VDI 4 (Ra 0.10 um) or better, which is a mirror-class finish that eliminates manual polishing in many mold applications. Copper electrodes with fine-pulse settings can achieve VDI 0 (Ra 0.05 um) in optimal conditions for optical-quality tooling. Surface finish on the AL1000G matches or exceeds what is achievable on smaller Sodick machines — size does not compromise surface quality.

The sinker EDM Z-axis performs two functions: controlled descent into the workpiece during the cutting phase, and rapid jump cycles to flush debris. Linear motors excel at both. During cutting, the frictionless linear motor provides sub-micron servo response to gap voltage signals — the machine responds faster to approaching short-circuit conditions, reducing the frequency of recast layer buildup. During jump cycles, the 1.2G acceleration achieves the electrode velocities needed for no-flush EDM on large cavities. A ball-screw Z-axis cannot match either the servo responsiveness or the acceleration of the linear motor on a machine of this size.

Large-format linear motor sinker EDMs are built to order. Lead times for a new AL1000G are typically 6-12 months from order depending on configuration and Sodick's production schedule at the time of order. Factor this into project planning — shops planning to bring new large-die work in-house should initiate the procurement process well before the capacity is needed. Sodick's North American distribution network can advise on current lead times and available demonstration machines for pre-purchase evaluation.