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The new HEAT nozzles are typically set to within 0.300” of the work piece, which can easily be an “eye-balled” operation. This makes setups easy and fast, and actually helps to make operation safer by eliminating the potential of machine crashes of the machining nozzles into the work piece or into clamping/fixturing.

Keep those questions coming to Jeff.Kiszonas@makino.com!

I just spoke with another HEAT customer, and he was VERY pleased with his test cut results...

He told me that he currently cuts this on a competitor's machine, and his cycle time is about 40 hours…compared to our 16 hours! So that’s a 60% reduction in cycle time! This customer also stated that he has cut these parts in a different model machine from the same competitor in about 36 hours. He wasn’t sure if there was something that he or his setup guy was doing wrong on his machines, but he did state that because the plates are not perfectly flat, they typically set the upper head to within 0.015” of the highest point on the plates. I also discussed with the customer that our HEAT technology does not require sealed off conditions, and that our heads (upper and lower) were set to about 0.300”  away from the plates. He seemed impressed with this, and he realized that this would make for easier setups within the machine. He also stated that a lot of their work (surgical instruments) has poor flushing conditions, so HEAT could possibly help him out in a very big way!

Competitor's machine: 40 hours
Another competitor's machine (same manufacturer with a newer, upgraded technology): 36 hours
Makino SP43 with HEAT: 16 hours…wow!!!

If you'd like to try HEAT, or have a testimonial to share, please email me at Jeff.Kiszonas@makino.com.

The HEAT modifications/upgrades for existing machines include 5 items:

1. New (special) nozzles
2. Pump/Plumbing modification
3. Replacement of mechanical filtration pressure sensor with a new digital sensor
4. New controller software
5. New machining conditions (power settings library)

A good question submitted the other day... here's the answer.

HEAT technology greatly increases the flushing pressure during non-optimum (poor flush) conditions. The standard poor flush technology (Both Away) uses pressures of 0.25 Mpa (36psi), where the HEAT technology uses 1.0Mpa (145psi)!

Received this question over the weekend. Here's a quick answer:

A machining condition that has a work piece that is completely flat on both sides (top & bottom) so that the machining nozzles can both be set to within under 0.008” (set to 0.020” on Makino). This close setting of the machine nozzles, which is very sensitive and critical, is done with the aid of a metal shim or gage.  In addition to the work piece being completely flat, their must also exist a 0.200” wide zone of material all the way around the working geometry/shape to maintain seal-off and maintain flushing pressure, and their can be no thru or cross hole interruptions during the machining process (work piece and cut are thru completely solid materials).  Any changes in any of these conditions will contribute to part inaccuracies, wire breaks, and greatly reduced machining speeds.

That really begs the question - what is a poor flushing conditon?

A poor flushing condition is any cut or process that does not allow one or both of the machining nozzles to be set to within the “optimum” nozzle setting of under 0.008” to the work piece. Poor flush typically involves non-flat work pieces that may include changes in part thickness, machined steps, thru holes, cross holes, counter-bores, etc.  Poor flush can also occur in a completely flat work piece as a result of the work holding setup. It is quite common to see a completely flat work piece not allow one or both of the machining nozzles to be set to within the “optimum” flush condition height as a result of the nozzles needing to be raised away from the work piece to provide clearance for work holding and clamping.

A follow-up to the entry dated Friday, October 20, "Email from an Application Engineer"

The engineer who sent the original email notified me of the following.

The user initially saw a 35% reduction in machining time over the conventional wire EDM processes. The job originally took 9hrs 36min, and now is running at 6hrs 36min using HEAT.

This same customer started using special HEAT wire from EDM Sales & Supplies on this job, and has been able to further reduce the machining time on this job to just 4hrs 39min - a 52 percent decrease in total machining time!

While HEAT doesn't require special wire, the HEAT wire will improve even further your speed in poor flushing conditions.

For a time-sensitve project or a job shop enviornment, these kind of savings are invaluable! For more info on EDM Sales and Supply, visit their website edmsave.com.

Received a question asking about the HEAT webcast we did a few weeks back. You can view it by registering here.

Also, we're going to have an updated webcast with a customer using HEAT talking about his experiences on Dec. 7 at 11 a.m. Eastern. You can register to attend that here.

You can submit any questions or HEAT testimonals by emailing Jeff.Kiszonas@makino.com.