Cormac MAGMA 4.0 machining centers EDM
MAGMA ELECTROEROSION MACHINES AND MACHINING CENTERS EDM
CORMAC ЅРА MAGMA U
CNC machine with 3 linear axes X,Y, Z and one rotary axís U .
Vertical Milling, Drilling, and Boring Machines
The rotary axis is incorporated in the ram with pneumatic electrode clamping/release, cleaning spray, and electrode clamped indication signal. Angular dimension readings are carried out by means of an encoder fitted directly on the axis with a resolution of 0.001 degrees. The machine is controlled by the Magmacontrol unit, with the possibility of interpolation of linear axes for cutting spirals or threads.
The machine has the following main features:
Large loading capacity of the table, thanks to the spacious container and high-precision needle guides on the longitudinal and transverse axes.
NC-controlled machine with four controlled axes: X, Y, Z, and U. The machine can be supplied with a linear magazine with four electrodes fitted laterally on the tank or with an 8-position rotary magazine fitted on the head to maintain reduced overall machine dimensions.
Generously dimensioned electrode carrier plate with grooves to facilitate the mounting of various electrode clamping tools.
Workpiece unloading and loading are facilitated by the double-door system on the working head, which moves on high-precision, pre-loaded roller guides with a long service life.
Other features:
High precision ball screws, low inertia motors, and a cost-efficient system.
The filter unit behind the container has high precision, pre-loaded roller blocks and filter inserts with a long lifespan.
The generator is of the latest design, with electronics of the newest generation, an industrial computer running MS-DOS, a 14" color monitor, and hard disk. The system also includes RS232 communication for external device connections.
The machine supports multitasking for simplified operation and programming.
The generator is failure-proof, with short-circuit protection, constant energy spark, and a short-circuit protection system that prevents abnormal impulses during operation.
Workcalc Programming System
The Workcalc software automatically programs fixed cycles and macro functions based on the operator’s input and requirements, making the process simpler and more efficient.
The machine supports ISO programming and features user-specific software designed to handle automatic programming, which simplifies operations and creates programs according to desired specifications.
The system ensures:
Automatic programming of fixed cycles and macro functions.
Support for ISO programming.
Fast filling and emptying of the work-tank.
The machine is designed for ease of use, ensuring precise operation and facilitating the machining process for complex geometries.
The design of the MAGMA CNC programmed by means of dialogue incorporates all elements required to guaranteeprogrammíng process, also during machine the followíng features: operation.
Version with telescopic tank
STURDINESS, SENSITIVITY, STABILITY, MULTITASKING PROGRAMMING
Friendly Programming, Compact Dimensions, Pallet Loading Facility, Ease of Workpiece Loading, High Filtering Capacity.
The Workcalc software automatically generates a program based on the electrode definition.
The main features include:
MAGMA CNC U
High-precision roller guides on longitudinal and transversal axes, enabling the loading of considerable weights on the large-dimension worktable.
This model is fitted with a rotary U-axis incorporated in the machine. It features three linear axes plus one rotary axis, interpolated and controlled directly by MAGMACONTROL.
Angular dimension readings are carried out directly on the axis with a resolution of 0.001 degrees using an encoder.
The drive is provided by a low-inertia motor with belt drive, free of backlash.
Automatic electrode clamping/release with cleaning spray and release warning signal, ensuring precise electrode handling.
Large-Dimension Electrode Mounting Surface
Equipped with T-slots and reference slots to enable installation of any type of electrode holder.
Telescopic tank constructed in stainless steel with four different height systems, providing free access to all sides of the worktable.
The machine can also be fitted with a 4-position linear electrode magazine or an optional rotary 16-position electrode magazine on the machine head, maintaining reduced overall dimensions.
Other Features
Automatic dielectric adjustment according to tank height.
Rapid tank draining and filling with filtered liquid.
Cartridge-type filter unit installed at the rear of the machine, with six cartridges ensuring filtering capacity of 5 microns. Easy maintenance and long service life are guaranteed.
Self-cleaning filter (available upon request) automatically cleans the dielectric liquid via a special system, with eroded material drained into a separate container.
Head Movement and Drive
Head movement on pre-loaded roller blocks.
High precision ball screws, ensuring accuracy and stability.
Very low inertia motors for efficient performance.
Fast filling and emptying of the work-tank.
Telescopic tank with 4 programmable heights.
Industrial Control and Power
Industrial computer running MS-DOS, 14" color monitor, hard disk, and RS232 serial port.
Power generator using state-of-the-art technology, incorporated into the machine and housed in enclosures fixed to the upright, ensuring high performance in terms of erosion speed and minimal electrode wear.
Safety and Reliability
Failure-proof generator with short-circuit protection.
Constant energy spark, ensuring stable and continuous erosion.
ISO Programming for flexibility and compatibility.
Fixed cycles and macro instructions for easy programming.
Workcalc Automatic Programming System
User-friendly programming, thanks to built-in functions that simplify the programming process.
The Workcalc system automatically generates programs tailored to the specific requirements of the machining process, ensuring optimal results and efficiency.
This combination of robust construction, precision features, and intuitive control makes the MAGMA CNC an ideal erosion station for a wide range of standard machining processes.
MACHINE
The mechanícal structure of the machíne has been desígned and buílt keeping ín mind all the problems and needs of absolute sturdíness required by the erosíve process-
gíving very hígh precision and stability without any thermíc deformation.
The high precísion ball screws allow movements that require no cIearance.
The table roller guides grant a perfectly linear movement that has a long life wíthout
any wear and tear.
Large dimension worktables and large tank doors on the tank of the model, or the
telescopic system on the model facilítate access to the work to the telescopic tank oп the MAGMA a pallet can be used for automatic workpíece loading and offloading, ideal for standard machining processes.
MACHINE DETAILS
CONTROL UNITAND PC
The MAGMA system is equipped with a movable keyboard for manual operation and programming.
This solution provides ideal performance for machine command execution. The synergistic integration of the two units allows the operator to easily control the machine and perform functions such as:
Multiprogramming
Multitasking
Program storage with descriptive list
Programming through dialogue
Graphic help
Simulation of real-time graphics
Technological tables management
Electrode Magazine: The Electrode Holder Magazine enhances the machine's flexibility, enabling it to carry out complicated machining programs. It features a rotary 8-position magazine to provide greater versatility and efficiency during electrode management.
ROTARY AXIS
The U rotary axis is fitted іп the ram. lntegrated with a pneumatíc clampíng is assembled on high precision bearings and ít can be combined wíth the main Manufacturers spindle and electrode holders.
Thís axis can be used as:
A positíoning axis for the oríentation of the electrode in the XY Plane.
A continuous rotary axis with a programmable rotation speed of 0 to
A contínuous erosive axis for the erosion of spirals, slots and axis can either interpolate or not with the other machine axes.
ELEKTRODEN MAGAZIN facilitating access for maintenance purposes.
A self-cleaning fılter is available on system enables automatic filter cleaníng with separation and discharge of material into the relatíve container.
The machine is equipped with two tanks for contaminated liquid and filtered dielectric. The contaminated liquid is taken from the latter and delivered to the work. The machine's reduced space requirement and ease of accessibility for maintenance are key benefits.
The machine features an Erosion Axis designed for processing spirals, grooves, and threads, in combination with interpolating linear axes for additional operations.
The filter unit, located at the rear of the machine, helps maintain a constant clean liquid supply and ensures easy and low-cost maintenance. The self-cleaning filter system is also available as an option, automatically performing the complete filter cleaning, including the separation and drainage of eroded materials into a special container.
GENERATOR AND OPTIONAL ACCESSORIES:
The generator is integrated into the machine to minimize overall dimensions as much as possible. Built with state-of-the-art electronic technologies and a European modular structure, it includes self-diagnostics for easy, quick, and accurate assistance.
Standard generator: 80 Amp with optional 120 or 160 Amps.
Programmable time base: Operates with quartz-controlled time units, adjustable in microsecond steps.
Current adjustability: The current is set in steps.
Short-circuit protection: Equipped with a protection system, an exclusive spark control system, and an energy regeneration system for increased efficiency.
Voltage range: The generator is designed for various operating voltages, ensuring high safety and reliability.
Additional optional equipment includes:
Fume Extraction System
Dielectric Cooling
Fire Extinguishing System, complete with a fire extinguisher.
GENERATOR
In the Numerical Control Erosion System, the operator is asked to input the following data:
Erosion parameters such as power, arc life, etc., according to the material, the electrode, and the part, the electrode surface, and the desired surface finish.
Erosion coordinates on the part, which are determined through linear trajectories, such as linear movements, various paths, orbital movements, etc.
The MAGMA system allows operation in three different modes:
Determination and insertion of the best erosive parameters in the machining program by the WORKCALC software.
WORKCALC allows the operator to input machining data, such as the electrode shape, material, machining type (roughing, finishing), and specify whether the operation will use one or more electrodes.
WORKCALC analyzes the data and automatically creates the program, determining the heights, roughness, spark and pause times, and electrode wear.
Electrode path programming in ISO language
The MAGMA system automatically controls the return of the electrode during the washing stage without interruption in the program.
Elaborate paths programming, such as widening, orbitals, etc., by means of M-functions.
The M-functions allow for complex motion programming in the fixed cycles, and the answers to questions are input in a dialogue format.
These three operational modes can be used simultaneously or interchangeably during the edit phase. The programs edited in any of the three modes of the MAGMA system can be previously simulated with the GRAPHIC simulation to verify their correctness.
Fixed Cycles
The MAGMA system includes various fixed cycles, which are used to simplify the programming of common operations, such as:
Workcalc programming system to create automatic programs.
Macro programming to manage complex tasks efficiently.
WORKCALC
The WORKCALC software enables the automatíc entry of machining parameters and work phase cycles.
The computer automatically selects ideal parameters from databases in the memory, and
stores them in the machining program.
The WORKCALC entry sequence is as follows:
The main page enabIes the selection of varíous electrode/workpiece combinations with the choice of the various technologies available for stopped and through cuts
The shape of the electrode can then be defined Ьy selectíng the relative geometrical pattern: parallelepiped, cylinder, cone or frustum of cone, pyramid or frustum of pyramid, etc.
Electrode shape definitions are completed by entering data for specífıc solid dimensions or different sections up to five .
All machining data base tables can also be displayed, íncluding CORMAC and USER data bases user-defined databases .
The required machining method can now 6e selected: roughing or finishing or a roughíng and finishing cycle to be carried out using the same electlode
WORKCALC now displays machining parameters which are optimised with respect to
machiníng time and electrode wear and calculated automatically on the basis of various u
heights, dífferences in electrode sections, and required roughness
Fig. 2
These data can be confirmed or modifıed; modifıed data can be stored in the user data base. Workcalc then compiles the entire machíning program automatically and the operator simply has to start the process.
ISO PROGRAMMING
The trajectory programming in the MAGMA system has been simplified by using the elementary language of the ISO Programming System.
Therefore, blanking operations are possible by compiling a series of blocks with movement coordinates as well as macro-instructions regarding movement and generator start-up/shutdown.
The MAGMA system automatically performs the necessary back-slide travel for the cleaning process.
The following programming example illustrates the internal blanking program of a square base pyramid with rounded corners, performed using a conical electrode.
Programming Example: Blanking Program for a Square Base Pyramid with Rounded Corners (using a conical electrode)
G90 F24 - Absolute movement feed
G0 X0 Y0 Z50 - Starting point
M51 - Generator on
G0 X0 Y0 Z0 - Quick movement
G0 X40 Y0 Z0 - Quick movement
G1 X50 Y0 Z0 - Linear erosion
G1 X50 Y40 Z0 - Linear erosion
G2 X40 Y50 R10 - Circular erosion
G1 X-40 Y50 Z0 - Linear erosion
G2 X-50 Y40 R10 - Circular erosion
G1 X-50 Y-40 Z0 - Linear erosion
G2 X-40 Y-50 R10 - Circular erosion
G1 X40 Y-50 Z0 - Linear erosion
G2 X50 Y-40 R10 - Circular erosion
G1 X50 Y0 Z0 - Linear erosion
G1 X40 Y0 Z0 - Linear erosion
M70 - Generator off
G0 X0 Y0 Z0 - Quick movement
G0 Z50 - Quick movement
G99 - Program end
Geometrical and Editing Functions
The control is also equipped with all the necessary geometrical and editing functions, including:
Linear interpolation of 3 or 4 axes
Circular interpolation of 2 out of 4 axes
Incremental and/or absolute programming
Translation of coordinates
Rotation of the coordinates
Scaling factor
Specular image (mirroring coordinates)
Subroutines and calls linking
Label jumps
Complete editing functions
fiXED CYCLES
MACRO-INSTRUCTIONS
The MAGMA system supplies the user with many fixed cycles which allow to obtain complex geometry by programming símple M functions.
Functíons can be programmed simply by entering the relatíve number in response to the
questíons displayed dialogue programming .
This operation is simplified also by graphícs displayed simultaneously with the questions to íllustrate the varíous functíons.
THE FIXED CYCLES AVAILABLE CAN BE DIVIDED INTO TWO GROUPS:
Cycles whích can be made in automatíc mode:
lnternallexternal centring functions.
Linear erosion with or without any final timer.
Cylíndrical orbital with central return.
Cone in openíng and closing.
Circular pocket cylíndrical widening .
Asynchronous cylíndrical orbital.
Square widening.
Pyramíd with square basis.
Star erosion.
Ortogonal multiple erosion.
Polar multíple erosion.
Políshing, etc.
Cycles whích can be made ín manual mode:
Complete centering functions, both inside and outside.
Centring by means of spark on request .
OTHER MODELS ARE AVAILABLE 1N OUR PRODUCT RANGE,
INCLUDING:
TANK TRAVEL -
MAGMA BASIC 200 700 / 450 / 330 280 / 200 l 200 40/60/80
MAGMA BASIC 200 E 800 / 500 / 330 450 / 300 / 200 40/60180
MAGMA BASIC 280 E 920 / 500 / 330 450 / 300 / 280 40 / 60 /80
CNC
Available on request: rotary axis and electrode magazine.
MAGMA CNC 800 / 500 / 330 320/250 / 200 40/60/80
MAGMA CNC E 800 / 500 / 330 4501300 / 200 40/60/80
With possibility of rotary axís and electrode magazine
Special modular model with longitudinal traverse obtained with the mobile upright. Rotary axis and electrode magazine available on request.
MACHINE MACHINE MAGMA 1 MAGMA UAGMA UC
X tabe travel mm 650 650 650
Y table travel mm 500 500 500
Z table travel mm 550 550 550
Rapid travel mm/min 1000 1000 1000
Axes resolution mm 0,001 0,001 0,001
Positioning precisíon 0,003 0,003 0,003
Tank length mm 1200 1200 1200
Tank width mm 800 800 800
Worktable dimensions
Platen dimensions
FILTER
Technical Specifications and Features for MAGMA Systems
Filter Specifications:
Number of Cartridges (Einsätze): 6
Filtering Capacity (Filtrierleistung): 0.005 mm
Liquid Quantity (Flüssigkeitsmenge): 1100 Litres (for both MAGMA U and MAGMA UC)
Rotary Axes (Drehachse):
Rotation Speed (Elektrodenzahl): 0/50 rpm
Max Electrodes Weight (Max Elektrodengewicht): 10 kg
Max Torque (Max Drehmoment): 10 Nm
Resolution Degree (Auflösung): 0.001°
Positioning Precision (Positioniergenauigkeit): 0.003°
Clamping Force (Spannkraft): 2500 N
Linear Electrode Magazine (Geradliniges Elektrodenspannsystem):
Max Number of Electrodes (Max. Elektrodenzahl): 4
Max Non-Contiguous Diameter (Max. Durchmesser): 120 mm
Max Single Electrode Weight (Max. Elektrodengewicht einzeln): 5 kg
Total Max Electrodes Weight (Max. Gesamtelektrodengewicht): 20 kg
Rotary Electrode Magazine (Drehbares Elektrodenspannsystem):
Max Number of Electrodes (Max. Elektrodenzahl): 16
Max Non-Contiguous Diameter (Max. Durchmesser nicht angrenzend): 120 mm
Max Single Electrode Weight (Max. Elektrodengewicht einzeln): 5 kg
Total Max Electrodes Weight (Max. Gesamtelektrodengewicht): 80 kg
Electrode Changing Time (Wechselzeit bei angrenzenden Elektroden): 15 sec
Dimensions (Platzbedarf der Maschine):
Width (Breite): 2350 mm
Depth (Tiefe): 2150 mm (MAGMA U) / 2750 mm (MAGMA UC)
Height (Höhe): 2800 mm - 3350 mm
Weight (Gewicht): 6500 kg (MAGMA U) / 6550 kg (MAGMA UC) / 6600 kg (MAGMA UC)
Work Table Dimensions (Abmessungen Arbeitstisch):
Worktable Dimensions (Abmessung Arbeitstisch): 800 x 480 mm
Platen Dimensions (Elektrodenträgerplatte): 300 x 160 mm
Min/Max Platen-to-Table Distance (Abstand min./max. Arbeitstisch / Elektrodenträgerplatte): 255 mm / 655 mm
MAGMASPARK Generator:
Max Machining Current (Max Arbeitsstrom): 80 Amps (optional: 120/160)
Max Removal Capacity (Max Abnahmeleistung): 1300 mm²/min
Capacitor Rating (Kondensatorenleistung): 0.001/18 µF
Voltage (Spannungen): 75V, 150V, 300V
Programmable Arc Duration (Programmierbare Funkendauer): 1 to 999 microseconds
Programmable Pause Duration (Programmierbare Pausenzeit): 1 to 999 microseconds
Additional Features (Sonderzubehör):
Fume Exhaust System
Dielectric Cooler
Fire Extinguisher System
Self-cleaning Filter
Tool Clamping
Oversized Tank for Workpiece Loading/Offloading
Enlarged Tank with Opening and Lid
Notes:
As part of continuous product improvement, all data and images may be modified without notice.
These specifications highlight the capabilities and versatility of the MAGMA systems, including electrode handling, precision control, and flexible machining.
