News Ecut

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 !

Quality = Purpose compliance
The purpose is that of the customer.
Among the more than 80 models of E.cut™ machines, it’s easier to find
the one that conforms to YOUR purpose.
Every model, from the simplest to the most sophisticated have
a reason to be according to the various needs of the user.

The CT fe CTH models, which can be supplied with both servomotors and stepper motors, have been the top of the E.cut™ production range.
High precision, high removal speed, and very important, a high removal volume/wire consumption ratio are the mandatory choice in many situations.
The precision tooling chooses the most sophisticated models, with very low machining tolerances and finish roughness. The cost of the machine, and the operating cost, will be lower than that of conventional wire erosion. E.cut™ is in this case ideal complement to conventional brass wire erosion.
The possibility to adopt different types of drive, and different types of control, facilitate the adoption of the “most suitable for your purpose” model.”

The small tooling will use a simpler model instead. Accuracy and roughness will always be excellent, but the modes of operation will be easier to handle. The cost of the machine will be much lower, such as to justify the purchase even with a low number of hours of use per month.
A new world opens up for many companies that do contract work. The adoption of conventional wire erosion is prohibitive, due to the high cost of purchase, the high cost per hour of operation, and often also due to the complexity of management.
Also for these models servomotors or stepper motors are possible; 3000 or 5000 controls, therefore with removal values, precision, and more or less easy management.
The wide range of models due to these combinations leads to sometimes surprisingly low costs.
And often the cost is also important

Beyond a certain size of workpieces, only E.cut™ has suitable machines in production. Working strokes up to 2600x1600x800 are uncommon, as well as the possibility to load workpieces up to 30 tons.
Many years of experience and the production of tens of thousands of machines has led to an in-depth knowledge of the problems of wire erosion on large size parts.
The design and manufacture of all parts within the same production area ensures that the final product complies with the purpose.

The construction of special machines and plants distinguishes the manufacturer from others.
The direct contact between the customer’s technical department and the manufacturer’s technical department guarantees the exact definition of the customer’s purpose.
The study of the solution is quick and detailed. In a short time all the technological and economic data are available for the evaluation of the investment convenience.
Not depending on external suppliers, the realization of the project takes place in a short time, and… certain.

E.cut ™  it’s only Genesi !     Not E.cut ™  ?     Not the same