Product category:
EDM wire cutting
News Release from: Mitsubishi EDM | Subject: Wire EDM
Edited by the Manufacturingtalk Editorial
Team on 17 July 2001
Wire EDM machines 'right first time'
As in the beginning we still try to 'sell' the benefits of Wire EDM, says Electrotech EDM Services, a finished part cut to micron tolerance in a hardened material 'right first time'.
As in the beginning we still try to 'sell' the benefits of Wire EDM, says Electrotech EDM Services, a finished part cut to micron tolerance in a hardened material 'right first time In the late 70s and 80s electro-discharge machining (EDM) was viewed as a 'black art'
This article was originally published on Manufacturingtalk on 22 Mar 2001 at 8.00am (UK)
Related stories
Wire EDM increases press tool capacity
With the CNC Fanuc and the Mitsubishi FX30 wire EDMs, you have automatic wire threading, so you can load multiple jobs or cut multiple apertures in a job, says Green Bros (UK).
CNC EDM centre frees up skills for toolmaking
To concentrate on plastics mould toolmaking and prototyping, and free toolmakers from routine machining, Algram has acquired an Ingersoll Center 4000 robotised EDM from Mitsubishi EDM.
In the late 80s and 90s its acceptance was growing to the point that for those who embraced it, the technology, in particular automatic wire feed, offered a first step in automating the production cycle.
More recently, it has been a way of increasing productivity without increasing manpower, and for some EDM has been the launch pad for a new company.
Such was the case for Wayne Warris, who set out in 1995 to offer a 24-hour sub-contract wire erosion service to those who could not afford the investment.
Further reading
EDM machine erodes highly accurate workpieces
Shown at EMO, the MA2000 EDM has been designed by Mitsubishi Electric and Ingersoll Funken Erosion to machine workpieces to within 2 microns.
Rivets automatically fed into stamping tools
Automatic system inserts rivets into dies during stamping operation to produce garage door components.
Plasma cutting of 75mm and 88mm thick SS plates
'Petals' to form welded thick section, large dia stainless steel dished ends were plasma-arc cut, producing edges entirely dross-free, while chilled water extended nozzle life by 600%.
Today, the company Electrotech EDM Services has grown from its initial investment in Wire EDM to be the largest subcontract user of Mitsubishi's wire technology.
'Since being introduced to wire erosion in 1990, I always believed that Wire EDM had a big future.' stated Warris.
'However, engineers generally and particularly those here in Sheffield were loathed in the early 90s to accept it as an alternative to traditional production technology.
There was also a reluctance to invest GBP100,000 + in what was seen as another way of producing electrodes when a 3-axis mill was both cheaper and a proven method.
Of course, today, toolmakers see the benefits in unmanned 24-hour production and Wire EDM as a precision tool.' 'My experience of EDM was with Fanuc and Agie, but I decided to thoroughly investigate the technology on offer.' added Warris.
'Of Mitsubishi, I was particularly impressed with the cutting speed, the feed rate of the wire, and the functionality of the controls.
I was also looking for a 'partner' that would help with the finance - between Mitsubishi and the Bank of Ireland they made life easier.
We started with a Mitsubishi 110SA a 450 x 320 x 265 submerged machine with automatic wire feed (AWF), but within 6-months the machine was fully booked out and we was able to finance the purchase of a Mitsubishi CX20.
It was important for me to consolidate the client base at this time whilst training operators and building up the capital for further investment.' Today, Electrotech have replaced the CX20 and increased its complement of Mitsubishi submerged wires to another 110SZ with FS, 2 x FX10s an FX20 and the recently purchased RA90 a 320 x 250 x 165 open flush wire with AWF.
They are complemented with a mix of Erowa and Hirschman wire tooling.
Drawings, IGES and DXF files (and soon to be installed solid modelling) see tool paths created using Mitsubishi's ESPRIT CAD/CAM package and DNC-linked to the wires down on the shop floor.
'As in the beginning we still try to 'sell' the benefits of Wire EDM - a finished part cut to micron tolerance in a hardened material 'right first time'.
A reduction in the number of operations and subsequent set-ups, relatively unattended operation - a 24-hour production tool cutting tool steels, brass, titanium, Nmonics and other 'exotics' as well as tungsten carbide - and I believe an inexpensive method of production' continued Warris.
'We are currently doing a lot of work with the medical industry, bearing industry, plastic moulding - inserts and cavities - and press tool sector.
Although an increasing number of companies now see Wire EDM as an affordable technology and have replaced traditional methods with it, I know there are still a large number of small subcontract engineering shops and traditional industries such as Precision Forging that could benefit from investigating its potential.
It is also important that the services that we offer are recognised by industrial sectors under increasing threat from low cost labour rates in the Far East, such as the Knife industry.
They can utilise a low-cost high-end technology for development work whilst they evaluate their production strategy.
We have in fact recently been contracted to do knife work that was previously blanked out, turned, milled and ground in two to three weeks that we can do from raw material in 7-days.' 'We continually look to evaluate the technology in the market every time we look to invest.
In fact, we have brought in off-line presetting this year and the Mitsubishi RA90 was purchased off the stand at MACH 2000.
In essence, as a wire erosion specialist we are constantly on the look-out the next technology breakthrough that will expand the service we offer.' concluded Wayne Warris.
• Mitsubishi EDM: contact details and other news
• Email this article to a colleague
• Register for the free Manufacturingtalk email newsletter
• Manufacturingtalk Home Page
Search the Pro-Talk network of sites
