Buy wire cut machine. Instructions on how to make an EDM machine. Benefits of EE wire processing

The EDM machines CUT P from AgieCharmilles were announced in April 2017. This flagship series in terms of its capabilities and the number of unique technical solutions is unmatched on the market.
Combining the IPG-DPS digital generator with the Quadrax mechanical design, together with additional automation modules, has once again raised the bar for wire EDM machines to new heights.
There are four models in this series with X-axis strokes from 350 mm to 1250 mm, while the workpiece weight is practically unlimited.
Quadrax designs are capable of cornering up to 45˚ across the entire workpiece height. No other wire cutting machine line in the world has such capabilities.
The use of the new version of the IPG-DPS generator made it possible to increase the processing speed by 15-20%, while the accuracy of manufacturing small contour elements has significantly increased. The surface roughness has also improved.
The thermal stabilization system, which maintains the temperature of the dielectric, the machine bed and all axes in a given range, guarantees high accuracy characteristics even when working in non-thermostated rooms.
The optical measuring system OMS facilitates workpiece binding, finding the center of starting holes and controlling the dimensions of finished parts - this facilitates the operator's work and saves working time.
A similar function is provided by the Renishaw stylus, which is integrated into the design of the wire cutter. Its use is especially important in combination with a pallet changer - in automatic mode, it monitors the position of the workpiece, including the inclination of the upper surface and make the necessary corrections to the program.
Also, the AWS and AMS modules are aimed at increasing the efficiency of the EDM machine in stand-alone mode. Which fix and automatically remove the falling out parts of the workpiece.
When looking at the Progress VP wire cut EDM machine, the words "imperishable classics" come to mind - externally, these wire cutting machines have remained unchanged for 20 years. This impression is deceptive - the element base of the generator has been repeatedly changed, new modules have appeared, the control system has been completely rewritten.
The level of technical solutions used in the design of machine tools is respectable. A comparable level of thermal stability, which Progress VP demonstrates during operation, is achieved by modern EDM machines with additional radiators, cooling circuits and tracking sensors. Here everything is decided due to the cabinet-type design and carefully thought-out placement of heat generating elements.
A whole bunch of unique possibilities are provided by the use of patented prismatic wire guides:

service life - 100 thousand hours
ability to work with wire diameters ranging from 0.05 mm to 0.33 mm
use of wires of different diameters and / or types in one program.

A wire cutter and a 25 kg spool as standard, together with the LOTO and AVTORESTART generator modules, are capable of providing the machine with an autonomous operation for 85 hours.

Features and characteristics		Travel dimensions X, Y, Z	Price in rubles: on request	Availability of equipment
AC Progress VP2	750 x 550 x 250 mm	350 x 250 x 256 mm		On order
AC Progress VP3	1050 x 650 x 420 mm	500 x 350 x 426 mm		On order
AC Progress VP4	1300 x 1000 x 510 mm	800 x 550 x 525 mm		On order
CUT P 350	1000 x 550 x 220 mm	350 x 220 x 220 mm		On order
CUT P 550	1200 x 700 x 400 mm	550 x 350 x 400 mm		On order
CUT P 800	1300 x 1000 x 510 mm	800 x 550 x 510 mm		On order
CUT 200 Dedicated	Ø150 ... Ø500 mm	350 x 220 x 220 mm		On order

Ultra precision wire cutting machine tools

CNC EDM machines from the Swiss company AgieCharmilles are designed for automatic production of precision parts in the instrument making, watch, and medical industries. This assumes the operation of the wire-cut machine as part of the robotic lines 24/7 and everything necessary for this is provided for in the design of the machines.
In addition to the technical solutions implemented in Progress VP, the design of these wire-cut EDM machines is based on a number of unique features:
The IWC module adds a second wire path and an automatic changer. You can choose to use different types of wire in one processing program, or two spools of 25 kg each will allow the machine to work autonomously for more than 170 hours.
The field of application imposes additional requirements on the accuracy of the processed parts. The integrated optical measuring system IVU is responsible for the 1 µm result. In addition to controlling dimensions and binding cycles, she was given the right to make changes to the control program so that the profile of the resulting parts was as close as possible to the specified one.
The AgieCharmilles OilTEch series wire EDM machines do not use conventional water as a working medium, but a hydrocarbon dielectric, as in piercing machines. This decision is dictated by the area of application for which they are designed. The use of hydrocarbons provides both undeniable advantages and imposes certain restrictions on wire-cut technologies.
Three main groups of tasks in which machines of this type are out of competition:

processing of highly corrosive materials;
the requirement for surface roughness is higher than Ra 0.05 µm;
production of carbide tools;

If everything is more or less clear with the first two points, then the last point requires decoding.
Manufacturers of wire EDM machines are silent about the fact that the cobalt binder is washed out during the processing of carbide in a water dielectric. Progress in this area is significant, but the tool life of carbide tools processed on a conventional wire-cut machine is lower than that of the same tool processed, for example, by grinding.
The use of a hydrocarbon (oil) dielectric solves this problem and the durability of the tool machined on a wire-cut machine is not inferior to the tool obtained with the help of other technologies. In this case, the surface roughness reaches Ra 0.3 µm.

Features and characteristics	Workpiece dimensions (L x D x H)	Travel dimensions X, Y, Z	Price in rubles: on request	Availability of equipment
CUT 1000	300 x 200 x 80 mm	220 x 160 x 100 mm		On order
CUT 1000 OilTech	300 x 200 x 80 mm	220 x 160 x 100 mm		On order
CUT 2000	750 x 550 x 250 mm	350 x 250 x 256 mm		On order
CUT 2000 OilTech	750 x 550 x 250 mm	350 x 250 x 256 mm		On order
CUT 3000	1050 x 650 x 250 mm	500 x 350 x 256 mm		On order

Video: AgieCharmilles CUT 2000 X, CUT 3000 X

CNC Universal Wire Cutting Machines

The EDM CUT E, introduced in 2016, is the first of the AgieCharmilles wire cutter family based on a new innovative platform. Main innovations:

digital generator IPG-DPS;
motor controllers and industrial computer from BECKHOFF;
AC HMI control system 2.

First of all, wire-cutting machines of this series are focused on use in tool production for the manufacture of dies and molds. These machines have the largest working tanks in their class, which expands their functionality. It is worth noting that in comparison with the previous series of wire EDM machines, the designers managed to reduce the dimensions. The front width of the machines of this series is 200-300 mm less than that of the main competitors. Much attention has been paid to improving convenience and safety, as well as ease of learning. It is impossible not to mention the legendary electromechanical collision protection, which was used for the first time in the world on the Charmilles erosion machines. When hitting an obstacle at a speed of up to 3000 mm / min, it protects the elements of the machine and the workpiece from damage and / or shearing, and also saves time, since it does not require re-binding the workpiece and money to buy new nozzles or wire guides. The management system has also improved. AC HMI 2 has received new functionality while maintaining ease of use, and the vertical screen offers more space for additional information.

The wire cut EDM machine is used for the accurate execution of holes in metals of various densities. The tool moves with high precision and smoothness. Engines for it are manufactured at a machine tool manufacturer using a unique technology.

Design

The wire cut EDM machine is equipped with plane-parallel motors. For this, manufacturers create their own neodymium magnets (NdFeB - neodymium-iron-boron). In addition to them, a unique K-SMS control system was required.

The classic wire EDM machine is only capable of processing electrically conductive workpieces. Metals are arc burned to a considerable depth. A smooth surface remains at the cut site, which often does not require additional processing.

The EDM wire cutting machine helps to obtain complex products: molds, strains, tapered and cylindrical surfaces, protrusions and bevels. On sale you can find two-dimensional assemblies used for the simplest operations. More complex products are obtained using five-axis machines.

Principle of operation

In the application process of wire cutting machine, brass wire is used most often as a cutting tool. It is made using a unique technology, and the speed and accuracy of processing depends on its quality.

If high-power pulses built into the described machine are used, the brass wire is equipped with a special coating. Its structure has several layers:

Base - CuZn40 or brass. Molybdenum, copper can also be used.
Thermal diffusion layer - zinc concentration over 50%.
The top layer is pure zinc.

Due to this structure, the wire has a number of advantages:

Withstands high temperatures.
The arc is stable during processing, the formation of sagging at the cut site is excluded.
Reduced wire consumption per cut length.

Wire EDM machines with CNC are mainly used in series production. Single products do not justify the purchase of expensive equipment, but some parts can only be obtained with this type of cut. The zinc coating ensures the continuity of the automatic process by eliminating the shedding of brass from high-frequency currents.

Processing process

Electrical discharge machining of materials is based on the formation of a spark by passing a high frequency current through a minimum air or water gap. This process occurs most actively with the participation of brass.

There are several types of metal processing on the given equipment:

Copy-stitching technologies.
Profile-cut.
Sewing.

More often the wire for EDM machines is attached to a movable unit. The workpiece is placed on a stationary table. The cutting process is controlled by the controller of the CNC system, which simultaneously controls several axes.

The essence of technology

The electrical discharge between the wire and the workpiece removes some of the metal. The emitted particles are discharged into the volume of the working fluid. Sludge (crystallizing particles) is filtered out and removed at the end of the cut. The processing speed is regulated by the amperage. But the optimal modes should be selected, in which no sagging is formed during the cutting process.

Erosion helps to make products with very thin walls, to process soft metals without mechanical damage. This cutting method is used for deep piercing. The thickness of the wire is minimal, only this parameter limits the diameter of the holes obtained.

Additional processing is not required, since no burrs remain after cutting by current pulses. It also does not require the expensive tools used in classical milling methods. This becomes relevant for workpieces made of viscous materials.

Equipment parameters

CNC process control expands the possibilities of metal processing by electro-erosion. The deviations of the perpendicularity and straightness of the movement of the axes are no more than 0.01 microns.

Mechanical accuracy is declared by the manufacturers, and no additional adjustments are required. The machine is completely ready for the start of an automatic cycle, it is enough just to load the part model in the standard code.

Modern electronics ensure movement accuracy due to angular and linear sensors, the resolution of which is equal to 1.5 microns. The accuracy of the resulting contours varies from ± 1.5 to ± 5 microns over a length of 300 mm.

The characteristics are selected individually for the needs of production. Based on this, the cost of equipment is formed, focused on a suitable model.

Additional options

The buyer of the machine with electric erosion can retrofit the equipment with the presented options:

Controlled position of the C axis. Most often required for milling cylindrical workpieces.
Turret with additional tool degrees of freedom. With the help of such a model, geometrically complex details are obtained.
The table can have additional axes. This option is used when processing body products or several blanks in one cycle.

The standard set includes systems for cleaning the working fluid, allowing filtration to be carried out with a quality of up to 3 microns. Dirty cartridges are standard sizes and change fairly quickly.

Wire-cutting machines with the help of current cuts strong metals and alloys - titanium, graphite, hardened and alloyed steel. In addition, they can perform grinding, cutting, lapping, copying, cutting out small and thick-walled parts, such as injection pins or medical needles. It is used for structural hardening, in which a dense metal layer forms inside, increasing strength.

How does it work?

An electric current is supplied from the generator to the workpiece and the electrode. The workpiece serves as a positive electrode - anode, and a molybdenum wire 0.18 mm thick serves as a negative cathode.

Under the influence of impulse discharges, the metal is cut, melted and evaporated, forming thin sections. The space in which the spark action occurs is washed with a coolant that carries away particles of the destroyed material.

Equipment advantages

The advantages of electric spark machines include:

Economical - the wire is used for several cutting sessions, so its consumption is minimal.
They are characterized by compactness, ergonomics and low energy consumption. Therefore, they can be bought for a small workshop.
The use of EDM machines reduces the amount of waste generated during metalworking, and the operator's workplace is always clean. This feature is important primarily when working with expensive metals and alloys.
Convenient models with CNC, which can work after setting up to 140 hours without operator intervention. Reconfiguring equipment takes only 15-20 minutes.
By adjusting the parameters of the electric current and the position of the wire, you can create products of different shapes, processing the workpiece in several directions at once.
The resulting products have a smooth and even mirrored surface that does not require finishing, which reduces production time.
Spark equipment is used in the production of complex shapes that are difficult to sharpen and mill.

Benefits of KMT

KMT offers to buy wire EDM machines from world brands that have proven themselves in metalworking in the countries of the European Union, Asia and America. The price is lower than similar European, South Korean or Japanese models.

All products comply with ISO and TUV standards for such equipment.

The company's managers will help organize delivery from a warehouse in Moscow to any region of Russia, installation and commissioning, production of a test part, selection of components and personnel training. Warranty and post-warranty service is provided.

The manufacture of complex parts is often difficult due to the need to maintain the dimensional accuracy of the finished products. Most often, this applies to the production of jewelry, automotive parts, tools, etc. In this case, the problem can be solved by using an erosion wire-cutting machine with CNC, which guarantees high accuracy and quality of processing of workpieces from any metal alloys.

Technical Features and Advantages of Wire EDM Machine

The operation of the equipment is based on the principle of electrical discharge machining, when the action on the surface of the workpiece is carried out not mechanically, but electrically. At the same time, the efficiency of work is extremely high, allowing you to obtain high-precision parts with flawless external characteristics. External defects, including minor ones, are completely absent, and the product does not require additional locksmith processing and does not need the control of highly qualified specialists involved in work at the final stages of production.

An important feature: only workpieces made of electrically conductive metal alloys are allowed to be machined on wire EDM machines. This allows them to be influenced by the methods of evaporation or melting of the surface layer. The machine electrode is a stretched wire located near the fixed workpiece. An electric current is discharged between the wire and the surface of the workpiece, and the highest voltage forms small micron-sized pits on the surface of the workpiece. With the help of water, side traces of erosion are removed, and the metal surface takes on a neat and attractive appearance. A layer of metal a few micrometers inward acquires a compacted structure and increased strength.

Currently, the wire-cut machine is used in the production of stamps, templates, cutters, and other elements. The presence of a CNC system on the equipment makes it possible to improve the production process and, at the same time, to simplify the maintenance of equipment. If you only intend to master a new direction of activity using a wire-cut machine, pay attention to branded used models. Their cost is lower, while the working resource remains high enough, and the equipment itself is completely ready for operation and does not require additional adjustment.

Buy wire EDM CNC machine at a bargain price in the KAMI Association

Branded samples of equipment at an affordable price - this is how you can characterize the offer of our company. Constantly in stock - a range of machines from leading manufacturers, which guarantee high productivity and quality of finished products. Our experts are ready to advise you on the ordering and operation of equipment, as well as to offer practical assistance in organizing its repair and maintenance. If necessary, you can use the service of selection and assembly of equipment for individual requirements.

Cut electrically conductive materials, from aluminum and copper to graphite and polycrystalline diamond. EDM technology allows you to achieve the utmost precision in the production of extremely critical parts at a relatively high cutting speed. At the same time, the capabilities of the machine are not limited to the manufacture of stamps and molds. Since only one tool is required to complete the job, this machine is an affordable alternative to milling, turning, grinding or broaching equipment. What's more ', a variety of other processes can be carried out with the multi-purpose EDM machine - even in automatic mode.
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Advantages of EDM Cutting Machines

EDM machine: eight steps in one

EDM technology eliminates up to eight production steps, including pre-machining, stiffening, finishing and billing, required in traditional machining processes such as milling, drilling and turning. The impeller (left) was manufactured using this technology. It is a highly economical cutting method.

Your possibilities with a wire cut machine:

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