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There is a new version of Machining Conditions now available for all SP-Series Wire EDM's.  This is Ver 501, and it provides settings for 3 Pass HEAT technology, more Precision Steel technology, and more Carbide technology.  The third pass HEAT technology adds a finishing pass, while the Steel and Carbide technologies have expanded settings up to 6 inch tall material.  Please contact Makino Technical support for more details at 888-MAKINO4 (625-4664).

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.