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Cost counts

The toothed profile on these tubes, (instruments for anthroscopy), has a derisory cost.
The calculation sheet shows the cost to the end customer as a fraction of a euro. The times and cost indicated are for the cutting of 17 overlapping pieces, so the values must be divided by 17, at a very low removal speed, to obtain a better surface roughness.
The overlapping of 17 pieces is random and due to the height of the clamp jaws. The clamp is a standard clamp, not made of stainless steel. It is not immersed, and the washing liquid, emulsion with normal water, is anti-rust.
The low cost of cutting with Ecut allows the use of wire erosion technology.
The precision, within 0.015 mm, the very low roughness and the absolute absence of burrs are the ideal solution for cutting these teeth.

The execution of this aluminium heatsink could also be carried out by mechanical machining, but there are several critical points.
The path of wire erosion is therefore the only choice. The difference between a conventional wire erosion and an Ecut™ is the cost per piece. In the case of a single piece the difference, a cost from 8 to 15 times higher, can also be ignored, but for a series of pieces, the total difference becomes very relevant.
If you have a subcontractor who owns an Ecut™ do the work, the savings, even on just a dozen pieces, would be significant, but if you own an Ecut™ the difference in cost becomes very important!

In the case of large diameter sprockets the division into sectors is quite common. In the case shown in the figure, the equipment adopted for normal wire erosion already available has been used.
With an Ecut™ it would have been possible to cut double arc sectors and overlap more pieces than those shown in the picture.
Already the smallest Ecut™ has strokes of 400mm x 320mm with a cutting height of 500mm. Moreover, the Ecut™ technology with a wire sliding speed 100 times higher than conventional wire erosion is not affected by the barrel effect, so it is possible to superimpose more pieces, in the picture there are only 2 pieces, one on top of the other, having the same identical size for all, without any reworking.
In the calculation sheet the values are for the cutting of 2 pieces of 20mm thickness, so times and costs for each rack must be divided by 2.

Keyless and broaching seats on large pieces. Slotting or wire erosion ?
Both !!
For small and medium sized pieces, and quantities of a certain size, the Slotting Machine is the compulsory choice. The costs of the tools are amortized in quantity.
When, on the other hand, the quantity is limited, often the single piece, the adoption of wire erosion becomes the most rational.
The reasons:
– Virtually no tool cost
– Simplicity of preparation and processing
– Accuracy within +/- 0.0075 mm on any height
– Machining of parts after heat treatment
With conventional wire erosion these advantages collide with the high hourly cost, especially if large machines are required.
With Ecut™ the operating cost is up to 20 times lower, making its use extremely advantageous.
Even with the smallest Ecut™ machines you can cut up to 500mm thickness, and with the biggest ones you can cut up to 800mm and have capacities up to 5000kg.
Spreadsheet times and costs are reduced in speed to achieve a good finish.

The piece in the picture is a classic example.
The stock removal machining presents some problems:
– the culisse is small in size and requires a special tool.
– The inclinations of the two sides of the culisse are different, so two special tools !
– The cut is very narrow and deep
– The final precision required is compromised by the cutting process.
The person who made the parts, a small company that carries out third party machining and owns two Ecut™, cut the indicated part after the heat treatment, obtaining optimal precision and finish.
The modification of many working cycles through the adoption of Ecut™ has brought great advantages. Advantages in terms of cost of parts, and therefore acquisition of new orders… and new customers

E.cut ™ is only  Genesi !  Not E.cut ™  ?  Not the same !

He bought an E.cut

Wire erosion. In any workshop it could be used daily.
Erosion cutting technology is uncommon, such as turning and milling, and is perceived as a machine tool for moulders. The relative complexity of its operation, and much more, the very high cost of both purchase and operation make it uneconomic to use in workshops where general machining is carried out.
E.cut™ has a purchase cost and an operating cost that overturn this reality.
Starting from 40,000 euro purchase cost, and an hourly operating cost of 0.50 euro/hour, it is possible to make cuts with a size of 400×320 mm, and a cutting thickness up to 500 mm. On any conductive material, of any hardness, with accuracies within 0.015 mm.

The following images show some machining operations.

The large-size bearing had some operating problems. It was necessary to cut it into two parts to understand why. Any other system would have compromised and altered the condition of the parts. With E.cut™ the cut was made with a few tens of euros.  The cut of 0.2 mm, left the two parts perfect, without any alteration of the surfaces.

Apparently these inclined slots look like a simple, executable milling operation.
The material, however, Inconel, has surprises in store for anyone who has machined it. The premature wear of the tools and the deformations caused by the heat developed in the machining process lead to a high final cost.
Machining with Ecut™ offers great advantages:
– Economical : Extremely low cost. Even with the simplest and smallest Ecut™ , and therefore the least expensive, cuts up to 400mm in length can be made. But, very important, the maximum cutting thickness is 500mm. This means you could clamp the piece at an angle, without any special equipment.
Simple programming. The profile of a quarry was drawn with the CAD on board the machine and it was enough to tell the CNC to repeat the same N times.
– Technological : No deformation due to lack of heat development. Impeccable geometries, tolerances within 0.015 mm, and roughness within 2.5 Ra.

In this process, notches are made on fairly large elastic grippers.
The removal machining on small workpieces does not cause problems, but when the workpieces become larger the execution of the buttonhole at the bottom of the notch becomes difficult. Wire erosion is ideal! But on workpieces up to 400 mm in diameter, the execution with erosion that allows such dimensions, becomes very expensive.

Already with the smallest Ecut ™ it is possible to make workpieces up to 500 mm in diameter, with notches up to 400 mm long.
The absence of the tank for immersion machining allows the use of a simple pneumatic rotary table. The rotation occurs at the end of each notch, automating the process. Once the execution program of the single cut has been filed, it is sufficient to tell the system how many times it must rotate.

Almost all the machines in the Ecut™ range have a cutting thickness of 500mm, some can reach 800mm. Few similar machines, which appear/appear in Europe, have these cutting heights, and the few have a much higher cost !
With more than 80 models in the catalogue, only Ecut™ is able to offer the machine “fit for purpose”.

Profiled cutting of a large aluminium beam over 450mm thick.
The pieces, obtained from profiled bars of a few meters, involve the ‘execution through different mechanical and manual processes: cutting into pieces, profiling the cut, and deburring.
The execution by conventional wire erosion has however a quite high cost, due to:
– The cut must be made in pieces, in order to contain it in the immersion tank.
– The interruption of the profile cavities makes it difficult to wash/cool the wire, requiring lower removal values, therefore longer cutting times,… and higher costs.
– On such high thicknesses there is a barrel effect that is eliminated with a second brush.
– For such high thicknesses, it is necessary to adopt large wire erosion, which is quite expensive per hour.

The adoption of Ecut™ is the ideal solution.
– It is not necessary to cut into pieces. There is no immersion tank and bars of any length can be cut.
– The interrupted cut does not affect the machining, on the contrary, it facilitates the washing.
– The geometry is perfect, at any height.
– Small Ecut™ machines can be used, with purchase costs from 3 to 8 times lower than conventional erosion with the same cutting capacity.

The adoption of Ecut™ has led to the acquisition of an important order!

Genesi has been distributing the machines produced by Baoma in Europe for over 12 years.

The machines are adapted to the European market according to the indications of our technicians; more than 150 machines installed in Italy and in Europe have suggested us how they should be made and what they should have.
Some modifications made only for the machines intended for the European market, and covered by three European patents, differentiate Ecut™ from similar machines that sometimes arrive / disappear.
The adoption of parts available in Italy, the stock of mechanical and electronic spare parts, the prompt assistance, the remote assistance, guarantee the full functionality of the machines, even of machines that have not been produced for years.
Operating systems of the latest generation CNC/PC,(W10 Pro), with regular license, Ethernet networking, remote programming, remote control, sophisticated manuals on board the machine with dynamic visualizations of the machine parts make Ecut™ fall within the parameters required by law for super depreciation.
The range of more than 80 models, from the simplest and cheapest to the most sophisticated, leads to suggest to the customer the most “conforming to HIS purpose” machine.
None of those offering similar machines has such a wide range.

E.cut ™ is only  Genesi !  Not E.cut ™  ?  Not the same !