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Was speaking to a customer the other day who was having some issues using coated wires, so I thought I'd share this tidbit...

When using coated wires, you may want to evaluate and/or remove the felt wiper pads from the upper wire drive system on your machine.  Depending on what type and brand of coated wire used, the abrasiveness of the felt pads can sometimes start stripping the coating off the wire.  This is more evident when using the newer Gamma-Phase type coated wires.  If the coating is being stripped off the wire from the felt pads, an accumulation of debris is typically seen near the felt pad above the AWT Thread Jet assembly.  This will typically not cause any major problems, but increases the maintenance required on the machine.

At Makino, we’re constantly testing new materials, new wires, and new techniques. We want to know what your real-world testing has taught you. Email Jeff.Kiszonas@makino.com and we’ll share your EDM tests.

One of our EDM Applications Engineers recently performed some comparison test cuts on a medical production job.  These results show comparative data between the Makino SP43 and one our competitor's machines, as well as between hard brass wire and Versacut H wire.  

Parts : KNEE REPLACEMENT PART (Medical Production)
Material : STAINLESS STEEL
Thickness: 2.500"
Wire Diameter: .012" (brass and coated)
Number of passes - 1 rough, 1 skim
MAKINO SP43 (WITH VERSACUT H)
Cutting Time : 1 Hour 25 Minutes.  (1.42)  (85 min)
Wire Consumption : 1071 Yards.
MAKINO SP43 (WITH HARD BRASS WIRE)
Cutting Time : 1 Hour 54 Minutes.  (1.90)  (114 min)
Wire Consumption : 1471 Yards.
COMPETITOR (WITH HARD BRASS WIRE)
Cutting Time : 2 Hours 20 Minutes.  (2.33)  (140 min)
Wire Consumption : 1647 Yards.
The Makino SP43 was:
25.4% faster in this application when using VersaCut H compared to hard brass wire.
18.6% FASTER than the competition when using Hard Brass Wire.
39.3 % FASTER than the competition when using VersaCut H wire.
And had:
27.2% Less wire consumption in this application when using Versacut H compared to hard brass wire.
10.7% LESS wire consumption than the competition when using Hard Brass Wire.
35% LESS wire consumption than the competition when using VersaCut H Wire.

Since this testing was done on the floor of a Makino customer, the competitor's machine was not tested with Versacut H.  I would expect, however, that even the competitor would see a substantial difference in cycle time and wire consumption by switching from hard brass to Versacut H wire, assuming of course that the competitor's machine can successfully run coated wires as well as brass wires.

There is a new development from Makino’s R&D engineers that I would like to tell you a little about.  Its called “Pico Precision Wire Guide System”.  This a new offering on SP and Uj series machines, and can be ordered from the factory or retrofitted to existing installed machines.  The Pico Guide System was designed to provide reliable, flawless threading of small holes in a tight matrix, or for highly accurate cutting of variable taper lands for stamping tooling.  This allows Makino to offer the only real “choice” in wire guide systems on a WEDM.  We will still offer, and believe that our standard Split V-Guide system is best for about 80% of WEDM work today, and will still offer this tried and true system. 

What kind of wire guide system do you use, and what problems have you had? Post comments or email me at jkiszonas@makino.com.

We were posed with a good question the other day - Why does Makino EDM take such interest in aerospace?

We have a long history of working with the aerospace industry.  As a supplier to all tiers of aerospace manufacturing, we have provided machine tools, spindles, machining centers, customized machines, turnkey systems, and part processing development to this industry.  It was only natural for us to want to help bring the aerospace community the latest information available concerning the use of EDM in manufacturing parts for critical aeronautical and aerospace applications.  

If today’s EDM machines leave little or no recast, HAZ, micro-cracking, or change in surface hardness, then secondary operations after EDMing, like milling or grinding, can be eliminated.  This would mean that the aerospace industry could now change their restrictive usage specifications for EDM that date from the 1970’s, and reduce time and expense related to these secondary operations.

Concerning the aerospace testing Makino has undertaken, if there are any shops out there that would like to specific tests regards materials and test types, please contact me to discuss specifics.

We are planning on testing some more alloys, including Inconel, and also expand testing to RAM EDMs as well.  If you would like to have a copy of the NADCAP Certified test results, send me an email, and I will send you an electronic copy. 

We want to help everyone in the aerospace industry by showing that the EDM process today can be used reliably and safely, without the need for secondary operations to remove damaged material, compared to the process equipment available even as late as 15 years ago.

If surface finish is the name of the game in your EDM world, SurfaceWIZARD is definately something you should look into. We have a webinar coming up this Thursday discussing the topic.

Register to attend at www.makino.com/events today!