Solving Vibration Challenges: Enhancing Machine Efficiency with Custom Vibration Damping Solutions

Solving Vibration Challenges: Enhancing Machine Efficiency with
Custom Vibration Damping Solutions
(Wire-Cut EDM Machines Installed on Spring-Viscous Dashpot with
Directional Stops)
Figure 1:Wire-Cut EDM ON Dynemech Spring Viscous Dapshots with
Direconal Stops
An Electrical Discharge Machining (EDM) wire-cut machine employs a
continuous, thin electrically conducting wire as the electrode to cut profile
on a workpiece. The method known as wire cutting is highly useful for
manufacturing metal parts with complex geometries.
Wire EDM is a very accurate and versatile manufacturing technique that is
particularly valuable in areas like as aerospace, medical, automotive,
Electronics , and tooling, where accuracy is extremely important.
Vibration-free setup for wire EDM machines because critical for various
reasons

1. Precision and Accuracy:
a. Wire EDM devices exhibit remarkable precision, allowing for the
fabrication of intricate features, thin walls, and fragile structures.
b. Vibrations that occur during the cutting process can cause
deviations from the desired cutting route, which in turn can
impact the precision of the finished product.
2. Electro-Thermal Process:
a. Wire cutting is the process of generating sparks in the spark gap
between the wire electrode and the surface of the workpiece.
b. The sparks created produce a high level of electro-thermal heat,
causing the material from the workpiece to melt and evaporate.
c. Even slight vibrations might disturb this delicate process, leading
to uneven cuts.
3. No Cutting Forces or Vibration:
a. Wire EDM, unlike conventional machining techniques, does not
produce cutting forces.
b. Vibration-free installation guarantees the stability of the wire,
making it easier to achieve cuts that are constant and precise and
help achieve smoother surface finish.
c. Insufficient machine rigidity can lead to tool chatter and poor
surface finish. Vibration should be minimized for optimal results.
4. Materials and Hardness:
a.Wire EDM has the ability to penetrate and cut difficult materials
such as hardened tool steel, carbide, and titanium.
b. These materials require meticulous handling, and any vibrations
might jeopardize the quality and accuracy of the cutting.
Essentially, it is vital to maintain a vibration-free environment in order to
preserve the high precision, accuracy, and reliability of wire EDM
equipment, necessary to ensure optimal performance in creating intricate
and precise metal components
Precision is critical in the modern industrial environment, since even the
smallest vibration can upset the delicate balance of high-efficiency
machinery and adversely affect the product output.. This case study
examines the innovative solution that Dynemech Systems provided to the
leading auto component manufacturer in India, where wire-cut machines
were experiencing overall productivity issues due to incoming vibrations.

The Problem: Incoming Vibrations Hindering Machine Efficiency
A leading automotive component company faced a substantial obstacle with
their wire-cut machine, a critical manufacturing process. Although the most
advanced EDM equipment was acquired, the presence of external vibrations
presented a significant risk to its overall effectiveness and accuracy.
Vibrations can significantly affect the precision and quality of machining
processes, potentially resulting in dimensional errors, problems with
surface finish, and increased wear and tear of machinery and toolings.
Given the importance of accuracy in automotive components industry, it
was essential for the client to resolve this problem in order to stay ahead
of their competitors and provide the highest quality products.
The Solution: Custom-Engineered Spring Mounts with Viscous
Damping and Levelling
Realizing the seriousness of the problem, the manufacturer sought the
expertise of Dynemech Systems, renowned for its innovative and
indigenous vibration control solutions. Following a thorough evaluation
and discussion with the client, Dynemech's team of engineers developed a
customized solution: custom-engineered spring mounts that incorporate
viscous damping and levelling mechanisms.
The metallic spring mounts, designed and manufactured by Dynemech,
incorporated viscous damping fluid to effectively absorb and dissipate
incoming vibrations. The implementation of this viscous damping
technology ensures that the wire-cut machine remains isolated from any
external vibrations, thereby preserving its precision and operational
efficiency.
In addition, the incorporation of levelling facilities in the mount design
facilitated effortless installation and accurate alignment, hence
augmenting the overall effectiveness of the vibration control system.

Figure 2: Spring-Viscous Dashpot with Direconal Stops
Results: Improved Efficiency and Reduced Rejection Rates
The incorporation of Dynemech's Spring Viscous Dashpot with Directional
Stops in the Wire cut EDMs were highly successful. The automotive
component company observed an instant enhancement in the overall
efficiency of their wire-cut machine, accompanied by a notable decrease in
problems caused by vibrations.
Significantly, since implementing the dampening solution, the manufacturer
has not encountered any rejections or quality control problems associated
with faults caused by vibration. The impressive result not only emphasizes
the efficacy of the solution but also showcases the concrete advantages it
has brought to the company's manufacturing operations in terms of
improved product quality and repeatability.
Although the Spring Viscous Dashpot solution successfully resolved the
vibration issues for the wire-cut machine, the automotive component
manufacturer recognized that vibrations from larger machines, such as
horizontal and vertical machining centres (HMCs and VMCs), continue to
exist on the shop floor. Nevertheless, the accomplishment of the wire-cut
machine dampening project has opened up opportunities for more
cooperation with Dynemech to tackle the lingering vibration challenges.
Conclusion: Tailored Solutions for Precision and Productivity
This case study illustrates the significance of tackling vibration challenges
in industrial environments and the benefits of collaborating with specialists
in the field of vibration management. By leveraging Dynemech's expertise
and extensive experience, the automotive component manufacturer
successfully improved the effectiveness and operational precision of their

wire-cut machines. This resulted in a consistent quality and minimized
rejection rates.
As industries continue to innovate to achieve manufacturing excellence in
terms of quality, accuracy and efficiency, the need for customized vibration
control solutions will inevitably rise. Team Dynemech, with their extensive
knowledge of vibration dynamics and dedication to innovation and problem
solving, play a greater role in assisting businesses in overcoming vibration
induced production challenges and preserving their competitive advantage
in terms of productivity, accuracy, and overall operational superiority.
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afety, #IndustrialApplications, #StructuralSafety, #EquipmentStability, #VibrationCo
ntrol, #MachineryInstallation,
Contact:
Dynеmеch Systеms Pvt Ltd.
Mob: +91-9810760131 ; +91-9911145131
Email: salеs@dynеmеch.com
www.vibrationmountsindia.com | www.vibrationdampingpads.com