At a cost…

At a cost…

E.cut and conventional machine tools, including wire erosion.
What is the fundamental difference?   The cost, but even more, the cost of ownership!
The machining of many modern materials with exceptional characteristics often involves devastating cutting problems.
Materials that are self-tempering or vary their mechanical characteristics if subjected to heat, materials that are difficult to chip, very hard materials, that wear out tools that are however sophisticated, (and still expensive!), machining to be performed only after heat treatments. Last but not least, the burrs! They must be removed, and often it costs almost more to remove the burrs than to process them.
Wire erosion! Often it is the only solution for certain machining operations on certain materials.
And for years it has been the solution adopted. But the costs of conventional wire erosion are so high that only particular sectors can afford it. For many processes the characteristics of traditional wire erosion are superfluous, and in these cases too expensive. So expensive that their use is discarded.

E.cut, with a total cost of operation, (current, wire, coolant, annual maintenance), which does not exceed 2 euros now, never, not even using the most ‘sophisticated models or large size, opens to use until before impossible.

Chromium Cobalt, alloy for prostheses, aeronautical material, engines… fantastic material that finds in 3D printing one of its most current uses, and in strong development!
But then you have to remove the pieces from the plate on which they were placed. And here the pains begin. Initially a band saw was used, but in addition to the waste of material due to the thickness of the tape, the delicate moulded parts were broken. Wire erosion was the obligatory choice, but the very high cost due to the very low yield, under penalty of wire breakage due to the difficulties of cooling, opened up the adoption of E.cut.
No problem of interrupted cutting or washing. Extreme ease of use, and very low operating cost.

The leaders of 3D printing adopt E.cut.

Stainless steels, and large workpieces.
Getting sectors from rings of this type seems a simple matter. Then when you are faced with materials such as stainless steel, Inconel, etc. the matter gets complicated.  You have to create rings with abundant surplus metals, cut with band saws, re-assemble everything, and resume turning again. Very high costs.
Here, too, wire erosion is the solution. And as long as the dimensions are contained, everything is ok, but when we exceed even only 300 mm in diameter, the costs spill! Large wire erosions have very high purchase costs, and operating costs, and around there are few!

E.cut has no washing tank. The smaller one can cut a ring with a diameter of 640 mm in two. At low water and operating costs compared to conventional wire erosion.

Large pulley in Chrome Nickel Cast Iron.
Executing the drive key on a height of more than 600 mm is not easy. If you are dealing with materials of this type, the matter becomes difficult. And above all very expensive.  If the diameter of the hole allows it, a large boring machine with an angular head can be used. Otherwise you need to have a large slotter, or find someone who does work for others. Maybe with wire erosion ……, but you have to rely on someone who owns one of these sizes, wait for its availability, and accept its costs.
In any case, the cost of running a simple key becomes truly remarkable.

With E.cut it becomes easy, and above all, very inexpensive!
Starting from the smallest models, the cutting height is 500 mm. But it is possible to supply models that cut 800 mm, and even 1000 mm. The capacities on the pallet start from 300 kg, and reach 5000 kg, with dimensions of the table that reach 1600 x 1000 mm.
And always without tank, therefore with dimensions practically without limits of the pieces to be worked.

Suzhou BAOMA is the largest manufacturer of EDM machines, with more than 20 years of experience, 50,000 square meters of indoor space, 300 employees. More than 48,000 machines installed in over 60 countries.

Genesi is the partner for Europe.

Suzhou BAOMA e GENESI saranno presenti alla EMO
Padiglione 13  Stand D85 Entrata West 1

The years go by

Eight years ago, buying an E.cut might have seemed like a gamble. A big gamble! The technology was almost totally unknown, and only a careful analysis and trust in the supplier, Genesis, had led to the decision to buy.  And in fact there were some initial problems, but with good will and attention in a short time we had “entered” the technology E.cut.
In the space of a year a second machine had been purchased, of large dimensions, and the experience was always increasing.
This allowed the company to acquire a large order from an important multinational company, and then, on the way, four accounts and three other new generation machines purchased.
Also considering that, with the technical additions made by Genesis, the machines are largely within the parameters required by law 2017 for over depreciation at 250%!

One of the fundamental points of the new law is in fact to help the introduction of digital aids in the production environment.
The company network of production machines, their control and management remotely, the “online” detection of the status of the machines, and the real-time accounting of the time spent.
These features were already implemented by Genesi on E.cut machines, and some have been added, to better adhere to the spirit of the law. (And of course enjoy the tax advantages!)
For example, the function of sending an email or a message if the machine stops has been added, in order to give the possibility to see the status of the machine remotely, and always remotely, the possibility to restart it.
The working diary of the machine can reside on the control of the machine itself, can reside on a networked server, or on a remote server made available by Genesis, and can also be consulted by Smartphone or Tablet.
The system provides to indicate the job in progress, and automatically detects from the machine itself the working status, stopped, and anything, without intervention of the ‘operator.

The CNC that controls the work of E.cut is based on a powerful industrial PC with W7 PRO operating system with regular license. This allows the constant updating of the operating system, and the protection from viruses and intrusions. The E.cut CNC can enter the Ethernet network at any time, so every customer has the benefit of remote assistance both from Genesis and, if necessary, directly from the manufacturer’s assistance service. ( Only E.Cut machines have this possibility ! ).
One of the implicit requirements of the law on hyper depreciation is the ease and simplicity of use.
E.cut has prevented time, being equipped with a manual on board the machine that can be consulted while the machine is working. In the manual, set up as a Windows Help, and also installed in PDF format, explanations with images have been privileged, and in many cases it is possible to view parts of the machine in 3D, with a program that allows you to rotate, zoom in, and view exploded views or sections.
Even non-specialized operators are given the opportunity to intervene quickly for maintenance and to manage the working parameters.

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We’re exhibiting at the EMO in Hanover.
Come and see our machines!
HALL 13 STAND D 85

And the stars are watching

E.cut is not the star of the workshop.
Like a Cinderella, it is often relegated to a corner.
Multi-spindle and multi-axis lathes, sophisticated machining centres, multi-axis controlled milling machines, and… expensive EDM machines are on display. They are the stars in the firmament of production departments.
But the current economic situation often leads to a reduction in quantities that puts the “stars” in crisis. In fact, sophisticated machines allow a reduction in costs, but at the price of high investments in equipment and tools, and long lead times and set up. Costs and times that with low quantities can no longer be faced.

The eight-tooth “stars” that can be seen in these images are an example.
You have to produce a few dozen pieces of stainless steel of various types, difficult and annoying to work. You must get a good finish, and very tight tolerances, within a hundredth of a millimeter.

And, as more and more often happens today, the delivery time was the usual “SUBJECT”. The time to create an ad hoc clamping system for the controlled milling machine and to obtain the tools suitable for processing these materials already exceeded the delivery times required.
The only solution seemed to be wire EDM. But the subcontractor/printer who was contacted in these cases did not give immediate availability nor certain dates. Not only that, but the price requested was definitely high.

E.cut processing has been carried out at a cost of about ten times less than any other method, including wire EDM with conventional machines. The realization of the clamping tool took less than an hour. In a single nesting all the teeth of the circumference are realized, with an excellent precision. Workpiece change in a few minutes, then hours of cutting without any operator, day and night, Saturday and Sunday.
An excellent job for the third party owner of E.cut.

And the stars were watching….

This a few years ago, with the first E.cut.

Now they’ve grown!

We’re exhibiting at the EMO in Hanover.
Come and see our machines!
HALL 13 STAND D 85