With Ecut, yes!

With Ecut, yes!


Large dimensions

On this large workpiece (over 2500 Kg.) and a cantilevered part of over 1000 mm, the internal toothing must be carried out. The execution by a third party, in addition to the considerable cost required by those who have a suitable hobbing machine, collided with the delivery time. The alternative could have been wire erosion, but even so the hourly costs of such a machine are prohibitive, not to mention delivery times.
Machining with an Ecut 63D has cost incredibly less than wire erosion, and even less than the hobbing machine.
The absence of the immersion tank allows the positioning of pieces with dimensions even far exceeding the table. The span between the heads of 500 mm, (optional up to 800 mm), allows you to place and cut pieces of high thickness.
The precision achievable, within 0,015 mm, ( +/- o,oo75 mm ), with roughness even lower than 1 Ra; the perfect geometry of the machined parts, without any barrel effect even at high thicknesses and with high removal speed, makes Ecut more and more widespread in gear manufacturing companies.

Aeronautics – Gas&Oil – Medical – Automotive racing

The use of increasingly sophisticated metal materials is increasingly widespread in high-tech sectors. More and more complex shapes for light and very resistant pieces are designed considering the great possibilities of multi-axis machine tools.
However, there are some problems:
The materials are often hard or bonded, so they are very difficult to remove from the tool.
More and more sophisticated machines are expensive, and… delicate.
Wire erosion is one of the methods to remove as much material as possible, and leave a minimum amount of chips to finish.
But wire erosion costs money!
E.cut™, has some great advantages over conventional erosion:
1) A 10 to 20 times lower operating cost.
2) The lack of a tank in which pieces and clamping tools have to be placed. This implies the possibility of working in a pendulum, loading one piece while the other is cutting, or the adoption of rotary tables, or dividers ….
3) Large cutting thicknesses even for the smallest (and least expensive) machines, with the possibility to cut more overlapping pieces and reduce the time of loading and unloading pieces.

.

Specimens of materials resistance

Providing certification of used materials is becoming increasingly important. For each casting, for each forged, for each semi-finished product from which a piece is obtained, it is increasingly necessary to provide the results of tensile tests, resilience, etc..
But the samples must be obtained!
Sawing, cutting, milling, turning… and at the end maybe the material has been “stressed”, and the test is no longer conclusive.
The cost then splashes, especially if it is difficult materials, (titanium, inconel, stainless steel, etc..).
Ecut™ is the ideal solution.
At an incredibly low cost you get the finished or semi-finished specimens, with centesimal precision, without stressing the material, and starting from any blank, casting, plate, laminate or forged.
The extreme simplicity of the Ecut™ control system and the possibility of archiving an infinite number of programs for each size or material give the possibility to employ poorly qualified personnel.

They look like Ecut!

E.cut™ is a registered trademark of Genesis.
In more than two decades, E’cut™ machines have become “different” from the originals still present in the original market.  The large number of installations in the most diverse sectors has led to the accumulation of experience that allows to direct those interested in these extraordinary machines to the most appropriate choice according to their needs.
The knowledge of the “European” mechanical processing, and the direct use for tests and pre-production has suggested changes and solutions that only E.cut™ machines have, and that are covered by patents.
Similar machines look like E.cut™, but they are not the same thing!

Gears, racks, toothed pulleys, keys, broaches!
Companies in the sector that use E.cut™ have a considerable competitive advantage.
In all cases where the equipment for the execution of a few pieces, (creators) would weigh heavily on the final cost, the use of E.cut™ revolutionizes the ‘obtaining of pieces.
-Accuracy within 0.015 mm.
-No barrel effect.
-Cutting height up to 500mm.
-Table capacity up to 3000 kg with standard machines.

Additives Manufacturing … the future is coming !
Ed E.cut™ occupies a leading position in Italian companies that print 3D.
The large cutting height, already from the smallest machines is 500mm, and the absence of the immersion tank make E.cut™ the ideal tool for cutting and detaching pieces from the plates.
The wire sliding speed, up to 100 times higher than the speed of conventional wire erosion, and the “drop” washing allow to cut the moulded parts in 3D easily, even in the presence of the interrupted cut.
Thanks to a system patented by Genesi, it is also possible to cut materials that cannot be processed with machines that “look like E.cut™”.
Genesi’s experience starts from the first 3D machines installed in Italy, and guarantees the most correct solution for any type of piece, and/or material to be cut.

Small parts and great precision.
The special feature of E.cut™ is the very low running cost, ( 0,5 €/hour for standard machines, and 2 €/hour for production machines ). Combined with the achievable precision (within 0.015 mm) and the lack of barrel effect even on high thicknesses, we have a “revolutionary” tool for many workshop processes.
With a very low cost compared to the purchase of any machine tool, and also compared to the purchase of a conventional wire erosion, E.cut™ is becoming the “new and different” investment for many small and medium companies.
As one user who bought two E.cut™s in one year said: “We have two more resources, but not two more employees!

Large pieces small costs.
Without reaching large models, ( up to 2600x1600x800h mm ), but already with the model 63, you can cut shapes up to 800 x 630 x 500h mm. And a piece weight of 3000 kg.
But the particularity of not having an immersion tank allows you to perform work on pieces much ‘larger than the work table.
The low operating cost, and the reduced investment of even the largest models, opens up new horizons for many machining operations.
The effectiveness of cutting any material, even the most difficult to cut by removal of chips, has led to radical changes in many work cycles, with savings unthinkable with any other system.
Genesi’s decades of experience and wide range of models guarantee the choice of the ideal machine for every need.

With Ecut you can

Cutting thin tubes often increases the cost of a product that uses them in an unbearable way.
Conventional mechanical methods leave burrs, are not precise, and deform the tube.
Laser cutting leaves burrs that are not easy to remove, and sometimes the materials to be cut undergo unacceptable alterations.
The accuracy achievable with water cutting is often insufficient.
Cutting by conventional wire EDM would be the solution, but having to work in a tank limits the length of the bars to be cut, and the cost is normally too high.
Ecut is the ideal solution for three reasons:
1) Not working in a tank, there are no limits to the length of the bars to be cut, and you can use systems to advance the bars, making cutting automatic.
2) The cutting thickness, 500mm, of the Ecut machines allows to cut more tubes. This is practically impossible with normal wire erosion because pressure washing is not effective in the case of pipes, and even less so in the case of several overlapping pipes.
3) The operating cost of an Ecut is max 0,5 euro/hour, about 20 times less than a conventional wire erosion.
This last factor is what makes you say: WITH ECUT YOU CAN!

The lack of an immersion tank and the cooling by means of a fall water jet, not pressure, gives the possibility to use Ecut as a production machine.
Fixing tools for the pieces to be cut can be placed on the whole pallet.  The pieces can be unloaded and loaded while working (there are no risks of any kind), having a continuous work cycle, without interruptions.
The plant can work in this way even unmanned, both during the day and especially during the night.
An operator can manage many Ecut machines.
In many cases there is no specific operator, but simple shift workers load and unload the pieces to be cut.
The very low running cost, about 0,5 euro/hour, is often the determining factor for the choice of this technology.
But the absolute precision of the cut, within 0.015 mm for any thickness and any removal speed, the total absence of burrs, the absence of alteration of the materials, and the possibility of delicate fixings on easily deformable parts, are all reasons for the choice.
Last but not least, cutting can also be non-linear, opening the door to new technological solutions.

Pulleys for toothed belts, gears, toothed wheels of various types are often made by wire erosion, when the hobs are not available and the quantity of pieces to be made does not allow the expense of a hob.
Other times it is a single piece, a gear to be replaced, a prototype.  Conventional wire erosion is therefore the solution, despite the high cost, and the waiting time by the subcontractor who has wire erosion.
With Ecut you can.
You can do it at a fraction of the cost, in a simple, fast way, and with absolute precision.
The Ecut numerical control is equipped with the program to generate gears, but the profile can be generated by any CAD system, and imported in DXF format.
A few simple steps send the program to the machine, and in no time, the pieces are ready.
Even the smallest Ecut machines can cut a thickness of 500mm (which is not normal, both for conventional wire erosion and similar machines). The absolute precision, (within 0.015 mm) and the lack of barrel effect, allow to cut very thick pulleys, or to overlap several pieces to be processed in one go.

Genesi has been distributing for over ten years the continuous wire erosion machines produced by Baoma.
With modifications and features to adapt them to the European market, they are distributed under the Ecut™ brand.
Some patents registered at European level, in addition to the manufacturer’s patents, make these machines “different” from those imported directly or occasionally resold.
More than one hundred machines sold in the most diverse sectors, to small, medium and large companies, have led to a knowledge of this technology, and to an experience in the use of the same that allows to direct the user, among the wide range, to the model most appropriate to their needs.
A laboratory with standard models and production models always in operation, allows you to perform tests, trials, and pre-production, with the realization of any equipment for clamping and positioning.
The large warehouse of spare parts and consumables guarantees the continuous functionality of all the machines installed, even those no longer in production, or no longer on the market.

Ecut™ is only GENESI, if it is not Ecut™, it is not the same thing!