Cost counts

Estimating the cost of machining is one of the most delicate phases of any project. For each part, and for each stage of implementation, the time and cost will be carefully examined.
The use of E.cut™.is an alternative that has been taken into account and used in small, medium and large companies in Italy and Europe for several years now.
There is more than one reason for the use of E.cut™: accuracy on high thickness cuts, simplicity of use, but the most important reason in the end is the very low operating cost.

SEE ALSO THE NEW “COST MATTERS”

We are often asked to provide times and costs for machining with E.cut™.
We have been using a simple spreadsheet for years, and decided to put it on our site, available to anyone who wants to check it directly, without sending around drawings or files that might be confidential.
It”s very simple to use, and the results can be printed and archived.
The results depend on the generator, (CNC) used and the speed of removal. If you already own E.cut™ machines, you already know everything, if not, ask our technicians the first time you use it.

The removal rates basically depend on the roughness you want to achieve.
The higher the removal speed, the higher the roughness will be.
But the removal speed, whose maximum values are often exhibited by those who are not thoroughly familiar with this technology, is not the most important parameter. Usually, in fact, high stock removal values correspond to higher wire consumption, unstable machining, and frequent wire breakage.
The choice of generator is also something to consider carefully. A more powerful generator and higher speed are matched by less ease of operation, hence the need for more experienced operators…
A quick comparison with our technicians will allow you to identify the model and CNC that best meets your needs.  ( we have over 100 different models of E.cut™ !)

CLICK HERE TO GO TO THE SPREADSHEET

E.cut ™ is just Genesi, if it’s not E.cut ™ it’s not the same !

E.cut™ at Kilometer Zero – From fairs, exhibition, end of rental –
Ask if your E.cut ™ is there.

For more than 30 years, these machines have been widely used in eastern countries for metal cutting and processing.
The basic reason for the widespread use is the low cost of operation.
The simplicity of the machine’s structure results in negligible maintenance costs, low incidence of breakdowns, and a decidedly low machine cost.
The ability to cut even with the smallest models very high thicknesses, up to 500 mm, with an accuracy within 0.015 mm and a lack of “barrel” effect, makes the system “revolutionary” compared to the expensive technology of conventional wire erosion

The following piece, designed and made with E.cut™ machines by G.E.S., ( https://www.gesingranaggi.com ) perfectly illustrates the great possibilities of the system.
It could have been made with conventional machining by removal, or with any conventional wire erosion, but the cost would have been at least 10 times higher.
With Ecut there are no tools to preset and load.
The ‘tool is the wire that makes a 0.2mm cut. The cutting path is obtained directly from the drawing in DXF format.
But the ‘aspect that makes it “revolutionary” is that this machining was performed in a small company, in which there could hardly have been wire erosion !!!
At G.E.S. in a little over a five-year period 3 Ecut machines have been installed, and the range of machining to their customers has been expanded.

Cutting, or a profiled cut of pipes or profiles is uneconomical with conventional wire erosions.
The problems are :
– Wire breakage due to uneven washing/cooling.
– Size limitation due to tank processing.
– Limitation of bar feed equipment due to tank machining.
– Limited cutting height with “normal” machines.
With the E.cut™ system these limitations do not exist.
– Processing does not take place in the tank.
– Wire washing/cooling is drop-in.
– Already from the smallest Ecut the cutting height is 500mm, and can be up to 800mm
– The lack of a tank makes it possible to prepare systems for bar feed.

The cut is without burrs, not altering the characteristics of the material.
Pipe fixing is “gentle” and does not cause deformation.

The simplicity of construction makes it possible to prepare large machines with working ranges practically impossible with conventional wire erosion.
Working strokes of up to 2000mm x 1200mm with cutting heights of up to 800mm and workpiece capacities of up to 6000 kg make wire erosion machining possible on large workpieces, with considerable economic advantages.
A modest cost favors its ‘use for machining operations hitherto unimaginable with wire erosion.

.

E.cut ™ is just Genesis, if it’s not E.cut ™ it’s not the same !

E.cut™ at Kilometer Zero – From fairs, exhibition, end of rental –
Ask if your E.cut ™ is there.

Periodically E.cut™-like machines appear on the European market.
These are machines from the Chinese market, not directly from the manufacturer, but from dealers or exporters who buy the lower cost, “naked” machines, paint them and give them a brand name. Often after a few years they close, and reopen under another name.
The needs in that market are quite different from those in the European market. Much lower labor costs make expedients to limit operators’ intervention secondary.
Genesi has been distributing the machines of one of the most important manufacturers for almost fifteen years.
Always having the various models available and in operation for demonstrations and tests, it has gained a great deal of experience, both with regard to machining and materials.
Important customers operating in very high-tech sectors, aeronautics, petroleum, additive printing, high-precision mechanics, are witnesses to the quality and reliability of E.cut™ machines.

.
Direct experience has led to modifications and additions , some patented, that make E.cut™ different from similar machines.
– SlipOn Facilitated thread insertion system on the rollers
– Isotensio, thread tensioning system
– Rotopower, system for processing aluminum
– Wire loading system with preset and adjustable clutch.
These expedients and modifications remedy deficiencies that others do not even notice !
These are expedients that in some cases are carried out and prepared directly at the factory under directions and drawings provided by Genesi.
The direct collaboration between Baoma and Genesi is very effective.

.

At ‘installation of the machine are loaded:
– Windows 10 PRO operating system in Italian/English,with regular license
– Manual in Italian/English in CHM format ( Windows help), and in PDF format of more than 400 pages, which can be consulted while the machine is working and from any PC, Tablet or Smartphone.
The manual includes the program for dynamic 3D visualization of the most important parts of the machine.
Included in the manual are schematics of the machine’s electronic boards
– Remote assistance and remote control system, ( both from Genesi, and from other company locations )
– Workmanager, a program for loading jobs and recording events in a machine diary. Work orders are remotely importable, and the event journal exportable.
– The graphics program ( Autocad 2005 ), and CNC software can be loaded into any remote PC. Programs can thus be processed in the engineering office, and sent to the machine.

The operating system, and other installed programs place the ‘plant ready and with the requirements of the laws for obtaining the benefits of Industry 4.0.

E.cut ™ is just Genesis, if it’s not E.cut ™ it’s not the same !

E.cut™ at Kilometer Zero – From fairs, exhibition, end of rental –
Ask if your E.cut™ is there.

The tax refund worth 50 percent of the ‘investment halves the cost of an investment in machinery or equipment that meets the requirements of Industry 4.0.
See in this regard pages https://www.genesigroup.com/ecut/requisiti-4-0/ and https://www.genesigroup.com/ecut/raccolta-dati-produzione/.
E.cut™ machines operate through an industrial PC on which Windows 10 Pro is installed with a regular license. The system is Ethernet networked and connectable to the company network. It is on the Internet to take advantage of remote assistance.
Well before the laws favoring the ‘adoption of computerized systems in production departments, Ecut was equipped with such features. Through an original Genesis program, Workmanager, it is possible to record the work to be performed, and performed.For work in progress, a machine diary allows one to see if and when the machine was working or stopped, and the cause of any failures. Workings to be performed can be uploaded from the production management system. The machine diary reports the current status of the job in progress, and events during the job are externally analyzable through the diary.

A simple data collection system makes possible a list of work to be performed, sorted chronologically by expected start date. Data can be entered directly by the ‘operator, or sent from a higher system.
The ‘operator enters the current job, the start of processing, and the status of work or stop.
Events are recorded in a journal, which is available to a higher system for data analysis and tracking the current status of the machine and the current job.
Switching from stop to work and vice versa is obtainable directly from the machine, (option).
On board the machine, it is possible to select the journal for each job.When switching from working to stopped machine, it is possible to set the ‘automatic sending of an email or SMS alerting of the change in status.

All machines are on an Ethernet network, and on the Internet.
Through TeamViewer, the most widely used remote assistance system, interventions are in real time. and direct control greatly facilitates ‘assistance.
Each machine is equipped with a mobile camera to remotely view details of the machine or workpiece.
Remote control shows the status of machining, makes it possible to stop and restart machining, and vary working parameters.
Through the same software it is possible to send/receive work programs executed in the CAD/CAM office.

On board the machine is the 350+ page manual, in Windows Help, (CHM ) and PDF format.
It can be consulted while the machine is working, and copied to other PCs, Tablets, or Smartphones.
Hundreds of pictures detail parts of the machine and are also available in 3D format, dynamically viewable.
The “Faults and Malfunctions” chapter shows step-by-step checks to be performed when faced with anomalies.
Extremely detailed is the “Maintenance” chapter, and there are wiring diagrams, both by element and by function.
The manual is made in order to facilitate immediate action even by not particularly experienced operators.

E.cut ™ is just Genesi, if it’s not E.cut ™ it’s not the same !

E.cut™ at Kilometer Zero – From fairs, exhibition, end of rental –
Ask if your E.cut™ is there.

The Ecut™ brand has been present in Italy for over 12 years.
The trademark registered by Genesi was created to distinguish these machines from those present in the original market, China.
In China, the cost of personnel is drastically lower, so the need for human intervention has a very limited impact on the final cost of the processed product.
In Europe, on the other hand, this human cost is much higher, hence the need for measures to reduce human intervention.
In the pictures we have put one customer per year of installation. In many cases you can see more machines. These are customers who, after the first, have purchased the second, the third…

Year by year the number of Ecut™ delivered has increased.
On the basis of the experience that was accumulating, different manufacturers were selected. The lack of the concept of “industrial product”, however, makes it difficult to distribute machines that have different components from year to year, not to mention month to month. Managing a spare parts warehouse becomes almost impossible. It’s a constant chase after manuals in Italian!
For over 10 years, the collaboration with one of the most important manufacturers of these machines, Baoma, a company that has a clear understanding of the concept of “industrial product” has led to the take-off of the sale of these machines in Italy.
The experience accumulated with models that are always up-to-date in the Genesi laboratory/warehouse, dedicated to the execution of tests and pieces for customers in the pre-sale phase, that is, the continuous use of the machines has led to the realization of modifications and special equipment, some patented, that make these machines different from the originals, and adapted to the needs of the Italian market.

Widespread from small to large companies, from subcontractors to mass producers, Ecut™ has often brought about a revolution in work cycles.
The difference in cost per hour, from 5 to 20 times lower than the cost of conventional wire erosion, has allowed the adoption of wire erosion technology where it was previously unthinkable.
Some features of Ecut™ technology
– No tank with washing liquid, therefore possibility of machining parts larger than the table size
– Cutting of high thicknesses, up to 500mm, with perfect geometry, without barrel effect and tolerances within 0.02mm: see cutting of keyways or internal teeth on large parts.
– Washing by gravity, not by pressure, so it is easy to work with “interrupted cut”. See 3D printed pieces.
– High wire flow speed; the wire “self-cleans”, having a homogeneous cutting environment even on relevant heights, without any barrel effect.
– Use of geometries in DXF or DWG format, therefore simple execution of complex geometries.
– System in Ethernet network, therefore remote assistance, remote control, remote program execution.

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

E.cut™ a Kilometro Zero - Da fiere, esposizione, fine noleggio -
Chiedete se c'è la vostra E.cut™ E.cut™ a Kilometro Zero - Da fiere, esposizione, fine noleggio -
Chiedete se c'è la vostra E.cut™

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 !

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

“We have two more resources, but not two more employees.” Says the owner of a small contract manufacturing company.
“Another center or another lathe is nothing new. An E.cut™ is getting out of the fray,” says the production manager of a small machining company.
The hourly operating cost of E.cut™ , dozens of times lower than many machining operations, leads to the use of this technology to change, sometimes radically, conventional working methods and taken for granted.
The result is often clamorously cheaper, and often technologically innovative.
The advantages of wire erosion cutting clash with the high cost of that technology. Only special productions in high value-added sectors can adopt it.
E.cut™ breaks down this barrier!
An hourly operating cost of less than 2 euros per hour, and an overall cost under depreciation that never exceeds five/8 euros per hour, combined with the simplicity of E.cut™ technology, open up new horizons.
Whoever is following this path, is out of the fray !

In small mechanical companies the modest purchase cost of an E.cut™ gives the possibility to have the technology of wire cutting at home, even without a high workload.
It is enough to have to turn to third parties for wire cutting. No more uncontrollable waiting times, and uncertain costs.
Where very hard and expensive materials are processed (aeronautical, gas&oil, racing,...), operating with very expensive and often delicate machining centers, the adoption of E.cut™ leads to the removal of as much material as possible, almost reaching the final height. No shavings, but often valuable scrap. Reduction in the cost of tools for the removal, and less wear and tear on the cutting machines.
In the sector of gears, pulleys, and rotating bodies, especially those of large dimensions, the possibility of obtaining keyways, even opposed and/or multiple keyways, up to internal gears, of high precision in a simple and safe way leads to a reduction of costs unthinkable with traditional systems.
The clean, precise, burr-free and material-free cutting of even complex profiles represents a revolution in the cutting of pipes or thin sheets. It is the cost of the E.cut™ system that makes wire cutting possible, convenient, and often unique.

One of the first manufacturers of these machines and a world leader in the sector, Baoma has been operating for over 25 years.
As the holder of dozens of patents, it is at the forefront in the search for reliable solutions.
For over 11 years Genesi has been distributing Baoma’s machines in Italy and Europe under the E.cut™ brand. Some European patents have been filed.
Materials, mechanical, electronic and software components of E.cut™ machines are specific for the European market.
The Genesi service center, deals ONLY with these machines. Spare parts for machines that have not been produced for years are available.
The large number of customers with more E.cut™ machines is the best proof of their reliability.

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

EMO 2019 Hannover
Also in this edition E.cut™ was present together with Baoma.
In addition to numerous patents, 3 Euro patents make E.cut™ a machine different from the original.
Different, to meet the needs of the European mechanical industry.
Different in the components installed, all strictly available in Europe, and of primary world brands.
Different in the realization of the mechanical part, with materials and parts of the highest quality.
Different in the electrical and electronic part, entirely made in the same production area.
Different in Europe for the mode ‘of assistance’ before and after sales that ensure the functionality’ over time.
Service interventions in a very short time on site, and a connection through tele assistance immediate and constant.

The largest mechanical company in the world, having verified the characteristics and capabilities of E.cut™, installed the first machine for one of its Italian plants in 2014, followed a few months later by a second one.
Having established the reliability of the plants and the readiness of the Genesi after-sales service, after a few years other machines were purchased to be included in very important production lines.
The latest Ecut™ has been included in a futuristic Additive Manufacturing department, a sector in which E.cut™ is the Italian leader.

RELIABILITY
In the country of origin of these machines, after two or three years of work are returned to the manufacturer who at little expense, resets them (!). Or they are thrown away!
Obviously this is not the custom in Europe.
The costs would be too high, so a machine must guarantee its functionality over time.
The following images concern one of the first machines sold in Italy. A few simple failures, which occurred as soon as purchased and ‘was promptly fixed, but after almost 12 years, disappeared the manufacturer, and no longer’ available important electronic parts, it seemed time to throw it away.
The deep knowledge acquired by Genesi in these years, has allowed to adapt new components to the old electronics, and, with a minimum expense to have the machine running perfectly.

The reliability, but much more important, the precision and accuracy of the workings have brought the spread in Italy to well over 100 machines installed.
In many cases the first machine was followed by others. From the small to the big company, the cheapness of working with E.cut has allowed considerable savings. Very often work cycles have been substantially revolutionized. In the following images, one of the most important Italian gear manufacturers has acquired two plants a few months later.
Purchased to cut keyways on large gears, once the precision and ease with which this precision is obtained had been measured, it was quickly passed to much more demanding and delicate internal gears.

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

.

Okay, it’s not always okay… It can happen! The important thing is that there is someone who can put things right. Whether it’s a new machine or a machine from ten years ago!

In the Genesi group we have created, for more than a decade, a structure that deals exclusively with these machines.
We believed it, despite the irony and sarcasm of those who sold conventional wire erosion.
We believed it and put our faces on it. Immediately, openly… in the sunlight.
We created a website exclusively for these machines. In the site there are all the information, the news, … there are our faces … in the sunlight.
There is the manufacturer’s description, and the link to his site, we clearly say who, where and how they are built… in the sunlight.
Every now and then some of the ironic and sarcastic people try to sell  machines similar to E.cut… not in sunlight.
They do not appear on their sites, if they appear you do not know where they come from, sometimes there are unreal images, sometimes there is generic and inaccurate information!

Selling other things, dealing with other things, they propose similar machines, often mimicking the name E.cut. Every now and then they change supplier, and… often disappear…

.
Says Mr. Franco, after years of using E.cut™:

“There are those who work in the twilight and those in the light of the sun …
Clarity, and a lot of experience make E.cut™ a winning machine suitable for all processes… its staff is always available and highly professional and guarantees quiet sleep to all its customers”.

He inspired us to write this new article!

They were among the first in 2005 to buy similar machines. But after a few years those who had supplied it disappeared!
When something started not to work, they got by for a while, but in the end they threw in the towel, or, worse, they threw in the machines. They couldn’t find the spare parts, especially the electrical ones and the cheap ones, installed by the Chinese manufacturer, in the meantime disappeared!
In 2019 they discovered Genesis, with its E.cut™.
They verified that the machines sold by Genesi arrive with standard components available on the European market. They have investigated at some customers to know the reliability of the assistance provided. They tested the machine at the Test&Lab in Genesis.

And they bought an E.cut™ !

.

E.cut™ is just Genesi, if it’s not E.cut™ it’s not the same thing!

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.

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.

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!

E.cut™ has exceeded ten years of presence in Italy.
Today the machines are very different from the first ones distributed, even if the founding principle is always the same. The drum that wraps and unwinds the wire is always the same, but the yield and precision have increased.
The close collaboration between Genesi and Baoma has made it possible to make changes and functions that make E.cut™ a product suited to the needs of the European market, and that make these machines “different” from those produced for Asian markets that sometimes someone offers “as they are”.

Changes and functions that result from field experience, the multiplicity of sectors in which more than one hundred customers operate, and the laboratory in which tests and samples are carried out.
The installation of the most recent operating system, ( Windows 10 pro ), allows to put the machine in the company network, to always have the connection in remote assistance, and to adopt manuals on screen in digital format. Compliance with the requirements of the 2017 law has allowed those who have purchased to benefit from the advantages of super amortization.

In these two years, with all these machines, there have been requests for assistance. The immediate intervention in remote assistance, or within the next day from the customer, have guaranteed the ‘operation’ of the machines.
The images are of some customers. They all have two machines, many have three, some six!
For all of them:

E.cut™ is only Genesis, if it is not E.cut™ it is not the same thing!

A love at first sight. It often happens with Ecut.
The young owner of this large company immediately understood the potential of Ecut. Having tried a demanding process at the Genesis laboratory, he ordered a machine. He assessed the punctuality of delivery times, the efficiency of installation and commissioning, and more importantly, the speed with which, under the guidance of Genesi’s technicians, his operators learned to use the machine and start producing.  In the space of three weeks, in view of the reduction in costs on machining operations previously carried out with removal machines, he ordered the second machine.

These parts could be machined by conventional machining.
The material, however, is a particularly difficult stainless steel. The very tight tolerances required, and the required unachievable milling finish, required grinding operations.
The part obtained with Ecut has tolerances well within the required values, the final roughness has avoided grinding.
No cost for tools, inserts, or special clamping equipment. In two placements the part is finished.
The cost is well below how milling could be achieved, and much lower than using conventional wire erosion.
The end customer was very satisfied. He paid a little less than usual, and the contractor who did the work earned a lot more than usual.

Tube processing is one of the areas where Ecut excels.
Not straight cuts, thin thicknesses, “cursed” materials, see wire erosion as the ideal solution.
But conventional wire erosion occurs in an immersion tank, which is often smaller than the length of the tubes. Moreover, washing “under pressure” is not very effective on a tube, and prohibitive on a series of tubes.
Ecut has no immersion tank, the cooling of the cut is obtained “by gravity”, and already ‘from the smallest machines’ has a cutting thickness of 500 mm.
The lack of the tank and the wide working strokes allow to mount more clamps, and to work “in pendulum”, obtaining an optimal productivity.
The completely burr-free cutting, especially in very thin thicknesses, makes Ecut a solution technologically, and economically irreplaceable.

Mr Alderighi’s company, Aldepack, is not a big company.
It is an excellence in the field of packaging machines, and exports all over the world.
The workshop is small in size (they have everything done outside). They take care of the design, and assembly. They have those few necessary machine tools, and every now and then they happened to do wire erosion workings, but it was always a pain. Costs “from molds”, delivery times never known, and often the work done not exactly as they wanted.
It’s unthinkable to buy one. For the high cost and never amortizable, and for the complexity of managing a wire erosion.
They asked Genesi to do some work, they saw the machine running, and Mr Alderighi, a mechanic for generations, “fell in love” with it.  The cost of purchase, the cost of operation, the simplicity of operation, have been the reason for the “fall in love”.
In the end, he bought it. They have changed the design of different pieces, simpler, more functional, more precise, (obtained after the heat treatments).
Spiritually, they sanctified her by putting a crown of light on it!

Ecut is just GENESI. If it’s not Ecut,… it’s not the same thing!

More and more gear manufacturers in recent years have purchased one or more Ecut.
Almost always the reason was to place side by side the cutters in order to be able to make larger sized keyways than those that could be made with the machines in their possession.
Even the smallest Ecut, in fact, the maximum cutting thickness is 500 mm.
But having an Ecut in the workshop changes the perspective from which to deal with processes that have always been performed in a certain way.
First of all, the execution of keyways! Obtaining them with Ecut costs less, much less than with a slotting machine. Because the precision to the cent, normal for Ecut for any thickness and width of quarry, costs much more with a stock. If you have to execute opposite seats, or more seats with variable angle, the simplicity with which they are obtained and the absolute precision make Ecut a “revolutionary” solution.
The next step is the execution of a broaching. If you do not have a broach for that profile, and the pieces to be made are few, obtaining it with Ecut proves incredibly economical. No broach to build, and immediate delivery of the pieces!
At this point we begin to discover that the tall piece with thin quarries is better suited to do with Ecut. And maybe even that pulley for toothed belts, those driving slots on large rings, those sectors of gear for a large diameter, or a particular rack ….

Location of the flash drive! We only need them for the keys, the high ones….
After not even a month, they are already making broaches, and some work that would never have been taken.

“Well! We used to make them out of stock. We have it, it doesn’t cost us anything anymore.”
But Ecut works alone. The geometry is perfect. Never that he pulls under or refuses. In the end it costs a lot, a lot less.

Not that easy, with that toothing ending in a joke. And then we didn’t have the creator, and buying him for those few pieces to make would have made the cost enormous. The customer was very happy, and we made a good profit.

These pieces were a real rotter. Almost 200 mm high, with those cables and those rounded edges it would have taken several shots. With Ecut, you only need one placement, one cut. Perfect geometry and tolerances.

Okay, just seat the thumb drive. But with Ecut’s 20 mm gears you can put 10 or 15 one on top of the other, and go, with a single placement you cut all of them. Perfect, precise, all the same. And since there is no bathtub, while it works you can place more….

A new way of cutting metals.
This is how Ecut was presented a few years ago. We are often asked what the novelty is. With the attention paid to mysterious and striking technological reasons, the disappointment in hearing that Ecut is a wire erosion, is expressed in a: “Ah, well…” which implies:” … nothing new”… And often the speech ends there.
But not always.
In fact, usually the question is: “So where’s the news?”
In the cost of operation, and in the cutting capacity
Ecut’s technology is wire erosion, but the difference is that with conventional wire erosion the wire is disposable, while with Ecut the same wire is used continuously, up to a hundred hours.

This has two important implications, an economic one and a technological one.

ECONOMIC ( operating cost ) .
Not throwing the thread the cost of operation is below two euros per hour.
The operating cost, 10 to 20 times lower, is the first “revolutionary” factor and leads to two immediate considerations:
1) wire erosion machining is economically possible before a prohibitive cost.
2) are absolutely uneconomical processes that can be performed with Ecut and that are still performed with conventional wire erosion.

TECHNOLOGICAL (cutting capacity)
The wire can flow a lot faster.
Running about one hundred times faster (about 700mt/min instead of 7mt/min) has great advantages:
1) the “washing” is by gravity, and there is no need for an immersion tank. Cuttings can be made on pieces even considerably larger than the tank.
2) thanks to the great speed the wire is “washed” by itself, the cutting gap is homogeneous and there is no “barrel effect”.
3) Very high thicknesses can be cut, even over 500mm, already with the smallest machines.

These considerations have been taken into account “on the fly” by the Villasanta brothers (MB). Grown on bread and shavings in their father’s company founded over 50 years ago, as soon as they saw the machine they began to think about all the times when they could profitably use it. the times when, having it, they would have acquired that order, and… much more important, what they could have done to us in the future.

VILLA EMILIO COSTRUZIONI MECCANICHE   –  VILLASANTA (MB)
Click per vedere il sito

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

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.

.

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

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

It would take a friend…
E.cut is the friend that any workshop man would want to have.
Small, compact, silent, easy to use, it makes with precision centesimal cuts geometrically perfect, on any conductive material. It does not dirty, it does not pollute, it does not make noise, it does not make shavings.
When it starts to cut, it doesn’t need anybody anymore. For work of a few minutes or tens and tens of hours, it works silently, alone, at an incredibly low cost.
No mechanical work in the workshop costs so little.
The following day the installation starts to produce.  You don’t need specific skills, nor specialized workers. In a few hours anyone learns to use E.cut. No traumas if missing who made it work.

We need an E.cut.
so you could forget…
… all the anger to be modified a simple keyway on a piece already ‘tempered. Transporting pieces, waiting, waiting… and spending, sometimes disproportionate figures.
And then sometimes it turns out that having an E.cut in the house even the seats of keys on new pieces would cost less, much less than doing them with the stool. The height becomes indifferent. Whether the thickness is a few tens of millimetres, or several hundred, the seat is always perfect, to the nearest cent, perfectly parallel even at high speeds ‘of removal. Enough tools that refuse, that pull under, that go from here and there. Whether it’s cast iron, steel, stainless steel, inconel, titanium… it doesn’t matter.
Pulleys, gears, bushings, cutter bodies. Whether it’s a keyway or a complex internal gearing, in a few minutes the cutting program is generated, the workpiece is placed, the tool is centred and… go. The machine alone, and the operator somewhere else!

We need an E.cut.
them, forever, in the workshop…
..even if the stockpile is already there. Yes, because when you need to make a profile different from the keyway you have to prepare a tool. And then you have to have the grinding or sharpening machine, maybe with the profile projector… and it’s not that anyone knows how to do it!
With E.cut it is very simple, and very inexpensive! Directly from the DXF or DWG drawing of the groove to be created you can see the cutting program and assign the inclinations of the rake angles. Place the raw tool on a normal vice (no expensive stainless steel tools) and start cutting. If you want an accurate finish you can perform up to 5 passes, until you get a roughness ‘less than 1 Ra.
In a few minutes the tool is ready! No expectations of the external supplier, or of the expensive technician of the tool department…, at a very, very, very low cost!

It took an E.cut.
to make this piece over 300 mm high.
Okay, the image is not very professional, but the young man who got this piece after only two weeks of using E.cut, without first knowing what a wire erosion was, was rightly proud of it. Okay, a few hours of tele-assistance with Genesis was necessary, but the result was excellent. Perfect measurements, strictly controlled in the metrological room, no barrel effect, excellent roughness and within the required values.
The lack of the creator with these measures and the ‘urgency led to try with E.cut.   The result was surprising from an economic point of view. No cost for the creator, nor the need to turn to external sources to obtain the piece of erosion at primary costs.
The company had purchased E.cut mainly to make keyways, but they found themselves having a “gear cutting machine” that for single pieces turned out to be an unexpected source of income.

E.cut 32D is the smallest, simplest, cheapest, and most …
not bulky of the E.cut models. ( see characteristics )
The characteristics of E.cut allow you to request the ‘hyper amortization to 250%, (see next article), and the forms of financing that we propose make it easy to’ purchase, (see mode’ of rental / financing)

Genesi’s efforts to make Ecut an avant-garde system, find these machines ready to fall within the characteristics necessary to ‘obtain the facilities provided by the budget law 2017 “Super depreciation 250%.
In the box below (Annex A of the law), the points where the Ecut system meets the required characteristics are highlighted in red.

EXAMPLE- (TAX ADVANTAGE)
If you purchase a “subsidizable” asset at a cost of €100,000, you can ‘proceed to the calculation of depreciation as if the cost of the asset had been equal to €250,000.

Cost of the asset = 100,000
Fiscal cost = 250,000
Tax savings (24%) = 60,000)
Actual cost of the asset = 40,000

Contact us, we will show you in detail, for each item highlighted, because ‘Ecut is part of the required characteristics.

All you need is an Ecut to find out how many jobs it can be useful in the workshop. One year after the purchase of an Ecut, two more have been purchased. “It has become the most clogged machine”, we were told. Purchased to profile carbide plates, “Since we made a key, no one wants to use the stockpile anymore! Even at great heights, perfect keys, to the nearest cent, with no one following the machine. You attack and leave, great!”.
In the following image, from a round of 900mm diameter, 350mm thick, almost a ton of weight, a complex internal profile of about 400mm diameter is obtained. No chips, but a nice block of precious steel to be used for other pieces.

On the contrary, these small objects in stainless steel, brass and silver are obtained with the same machine!
Of course, if only these processes were carried out, a smaller machine would be less cumbersome, but the precision and finish required are the same for a small or large machine.

On the contrary, these small objects in stainless steel, brass and silver are obtained with the same machine!
Of course, if only these processes were carried out, a smaller machine would be less cumbersome, but the precision and finish required are the same for a small or large machine.

Titanium and stainless steel tubes. Profiled cut. The full cutting height of the machine, 500 mm, is normally used. Machining also in commuter mode, so it is possible to unload and load the pieces while the machine is cutting the other column. The lack of an immersion tank allows placements and masks unthinkable with conventional EDM machines.

.

Sure, they grow like mushrooms…
Those who start using an Ecut quickly realize how many pieces can be made much more conveniently by changing the method of processing.
Obviously the technology of wire erosion is not a novelty, but the high hourly cost, the relative slowness if compared to conventional machining and the consequent high cost of realization of any machining, have relegated its use to the sector of moulds, and a few other sectors.
The low operating cost, and therefore the dramatic reduction in machining costs, represents a revolution in the mechanical machining sector.
One thing, however, is to say it, and another thing is to do it.

The following images are of customers who have touched with their hands the first machine.

The following image is of a customer who after a while was unable to do what he had bought the first machine for. Every now and then someone from the technical department would go to the workshop to smoke a cigarette… and then they would change the way they made some pieces. After a while they bought the second one.

They make rapid prototypes, they are among the leaders in Italy, and a machine was no longer enough.
For a question of size, … but also of growth of work.

These are a branch of the world’s largest mechanical engineering company. After only 4 months of use of the first machine they ordered the second one.

A few months after buying a very expensive Japanese car, they discovered Ecut. The smallest and cheapest Ecut does almost the same production as the Japanese. Tried it, and after a few months it took another one. Doubled the production with two machines and less than a third of the cost of the Japanese.

After two weeks from having installed the first one, the big one at the bottom, and having started to do some work, they decided to eliminate an expensive work, carried out on a very expensive machining center, and to buy the second one, the…

Here we had to widen the holes of 800 rollers. In the space of 18 months!
Once all the cutting parameters had been checked and the maximum removal speed had been obtained, another 3 machines were purchased. The total cost was however lower than the cost of a single Swiss machine. But the production has almost quadrupled!

Gas&Oil. After testing and trials with us, they wanted to buy four machines immediately. We suggested that only two of them should be medium in size. After one year, they ordered two more. One bigger, and one of the new C-Type model, faster.

For these simple processes the use of Ecut has drastically reduced the costs of realization.

The execution of this cradle on a series of only three stainless steel pieces requires at least two placements. The deep and thin cut presents risks of breakage of the cutter, the culisse has two different inclinations, therefore two different cutters. Cutters for conical slots on this material break easily…

The execution through Ecut takes place in a single nesting, the tool is the only wire, and the work program is obtained quickly with the CAD on board the machine:

This series of 16 Inconel pieces could be obtained by cutting the moving part with a circular saw, or with a band saw. However, the material is particularly difficult, and tool breakage is very frequent. The required precision is also quite tight.

With Ecut, a simple, little vice is enough to hold the piece. The lack of an immersion tank allows the workpieces to be processed with a long shank. The accuracy is within 0.015 mm, and the cut of only 0.2 mm. are the ideal solution from the technological point of view, and sensational from the economic point of view.

The same machining operations performed with Ecut could be performed with conventional wire erosion, but too often the difference in hourly operating cost, (over 20 times greater, 0.5 euros/hour Ecut against 15 euros/hour normal wire erosion), make this solution economically unthinkable.

With Ecut no tools, no heavy clamping, no swarf, no dirt,… and, almost always, no people!

In the shop, an old wire erosion is a very bad deal.

The advent and spread of the new Ecut wire cutting technology makes the use of old wire erosions obsolete and uneconomical.

In fact, the hourly cost of operating an old wire erosion is around 10 euros/hour, while an Ecut has an hourly cost of 0.5 euros/hour.

By hourly cost of operation is meant:
For old wire edm: Wire cost, distilled water, resins, filters, electricity, maintenance.
For Ecut : Wire cost, emulsion with normal water, filters, current, annual maintenance.

Considering 3 types of use:

1) Sporadic use 400 hours per year
2) Limited use 1000 hours per year
3) normal use 2000 hours per year

the related costs are :
Considering only the operating cost

Considering Ecut with operating cost + depreciation cost, and old wire erosion only operating cost:

It is clear that it would be much more convenient to “scrap” the old wire erosion and use a modern Ecut.

In fact, examining the values of the yellow line of the first table we can see that over 2000 hours the use of Ecut involves a saving of 19,000 euros / year. An Ecut would pay itself in a couple of years, only with the money saved!

If you go to the page HIRE, you can see how already ‘with 700 euros per month you could have an Ecut.

By renting an Ecut you will be more competitive, and you will save a lot of money!

In a large, historical company producing high technology mechanical components, Ecut, purchased for the execution of narrow quarries on heavy thicknesses, has revealed its considerable potential ‘after a few weeks of use.
“A new world has opened up for us,” said the workshop manager.
For the man, constantly in contact with the production problems, seeing the machine in work has been a light that turns on.
For many parts that have always been made with expensive CNC machines, such as spindles, tools, inserts, expensive clamping tools, and chips, swarf, swarf, etc., he can now use Ecut.

From CAD to finished part, no spindles, tools, inserts,… not even shavings.
At a ridiculously low cost compared to before!

NO MECHANICAL PROCESSING CAN PERFORM THESE PARTS AT THE SAME COST!

doubts ? CLICK HERE and request a machining quote

Some features make Ecut a different machine, and “new” in the field of mechanical processing.

1) the lack of immersion tank
2) the lack of the “barrel effect”

These large sprockets were made with one of the smallest Ecut, (40D). Although the machine strokes were not sufficient to execute the piece entirely, the lack of an immersion tank allowed with simple tricks to perform the work by rotating the pieces three times. The machined parts are not adjacent, there are about 20mm between one crown and another, and this makes it very difficult, if not impossible, the machining with a conventional wire erosion. With Ecut, no problem. The particularly difficult material, ( inconel ), is cut without any difficulty, and the cost is enormously lower compared to machining.

These parts are prototypes of a profile. The dimensions are 16×5 mm for one part, and 6×9 mm for the other. The length is 210 mm. Tolerances are +/- 0.02 mm. ONLY with Ecut it is possible to work like this ! The workpieces must be machined in a single pass. It is NOT possible to carry out rework, because such low thicknesses imply a deformation at the end of the first cut.

Running two simple flash drives wouldn’t seem to be a problem. But the piece is over 250mm high.
And this creates a problem!
Erosion machines that cut these thicknesses are starting to be particularly expensive, with a significant hourly cost, and those who own them certainly do not give the work!
The machine in the figure is the smallest in the Ecut range, it cuts 300 mm thick, with strokes of 400×320 mm.
The keys are obtained with a single cut, with a tolerance on the whole height within 2 cents.

NO MECHANICAL PROCESSING CAN PERFORM THESE PIECES AT THE SAME COST!

doubts ? CLICK HERE and request a machining quote

Nel Lecchese

These two machines work and produce without any additional personnel being hired. Operators who follow the machining centres have quickly learned how to operate them. Not only that, the working hours of E.cut are 24/7. Twenty-four hours a day, including Saturdays and Sundays. At an hourly cost that does not exceed three euros, including depreciation! When then in the technical office have understood what you can ‘do’, they began to redesign many details.
And one was not enough anymore!

Stainless steel fittings and parts for the food industry. Mechanical processing, moulding, and construction of its own moulds. It was enough to see it, feel how much it cost, how much is the cost of operation, and above all, the simplicity and ease of use to decide to buy it. To do what? “We don’t know, but a machine like this is always needed in the workshop”, and then, no person to hire.

In Mantua

Maintenance and regeneration of machines for socks. A myriad of metal parts, to be rebuilt. Gears, racks, small and complex cams, notches and cross-references. In the most disparate materials, with treatments and hardnesses that create a lot of problems to the mechanical working through tools. And always in limited quantities. With E.cut from the drawing with CAD to the realization of the piece is a matter of a few minutes. High precision at a very low cost!

In the Cuneo area

Young company. Mechanical equipment and moulds for sheet metal. Conventional wire erosion “didn’t fit”. And not only for a problem of space, but especially for a question of costs. And above all operating costs! At a similar price they could have purchased a conventional used wire erosion, but on the cost of operation of an E.cut, more than ten times lower, they focused their attention. Young people, but with proven experience in mechanical processing, it was enough to see the machine in work and perform some details to discover the reasons, and guess the great potential. One is there, but the place is for two!

Baoma’s constant research and development work has led to the presentation of a new series of machines in 2014. The most important aspect is the C-structure, but other important news are present.
Thanks to this structure, it has been possible to introduce a servo-assisted electronic wire tensioning system, patented by Baoma, which raises the achievable finishing level to less than 1 Ra of roughness.
The other important innovation is the new numerical control BMXP 5000. The CNC takes full advantage of the possibilities and power of the current computers on which the control software is installed. The higher speed has allowed to increase the controlled power, reaching 8 Ampere.
The combination of these new features translates into an increase in the removal speed of more than 60% compared to previous systems, reaching 250 square mm per minute, a roughness of 20% better, and an accuracy that rises to + / – 0.012 mm, improved by 20%.

(CLICK HERE TO SEE THE MOVIE)

E.cut Baoma is just Genesis.
…if it’s not E.cut, it’s not the same thing…!

Only Ecut comes to you directly from the factory.
No Chinese exporter, no parallel importers… breaking the chain.
Only through Genesis are you sure to have a product with all the European certifications

The four notches of these six large special hard steel ferrules, (45Hrc), were obtained without any fastening equipment, without any special hob or cutter, in one fell swoop. They cost about 20 times less than with normal wire erosion. An incomparably lower cost than normal milling.

Titanium’s a bad beast to cut. The best thing is to get as close as possible to the final measurement with erosion, and so it’s done. But here an E.cut is used. The 12 hours of work to cut these pieces, of pure cost are worth 6 euros with E.cut, at least 120 euros with a normal wire erosion. The precious, and expensive, wire erosion is better to stay still, or maybe do jobs that make it pay for what it costs!

Of course, it doesn’t happen every day that you have to work on such high or such long pieces. But when it happens, or you go out, with costs and expectations that everyone knows, or if you have machines so ‘capable, you do not look at what it costs. The smallest E.cut cut cuts a thickness of 300 mm, and an average machine has strokes of 800×630 mm, with capacities up to 3000 kg.

With a cost ranging from 30,000 to 50,000 euros, with the possibility ‘to rent a car in advance zero, for 60 months, and blackmail 1%, an E.cut and’ a minimum investment to make it more’ your machines!

E.CUT: News

Unfortunately, however, the blowholes, with their often non-conductive content, cause the wire to break frequently and make processing slow and annoying.
The automatic threading with which some wire erosions are equipped for the same reasons works poorly and often does not work at all. Pieces that should be performed in a few hours are prolonged, with no production, and ultimately expensive and no longer ‘convenient.

The new CNC that manages E:cut is installed on an industrial PC with a 32-bit Windows XP operating system. ( Previous systems operated in DOS, or under Windows 98 ).

The higher speed of the operating system has led to an extremely effective cutting control. The setting of the machining so that if there are difficulties in cutting the wire backs up and tries again several times, eliminates the breakage of the wire.

The new CNC that manages E:cut is installed on an industrial PC with a 32-bit Windows XP operating system. ( Previous systems operated in DOS, or under Windows 98 ).

The higher speed of the operating system has led to an extremely effective cutting control. The setting of the machining so that if there are difficulties in cutting the wire backs up and tries again several times, eliminates the breakage of the wire.

XP also allows the Ethernet networking of the PC, then installing a remote control program, you can control the progress of the cut, but, importantly, you can remotely control the machine, so, in case of a stop, you can ‘give a further retreat, and normally you can continue the work even without being present.

Tests carried out have led to a 4-fold reduction in the execution time of a series of pieces. The intrinsic hourly cost of Ecut, about 10 times lower than a conventional wire erosion, has reduced the cost of about 40 times!

CO2, Greenhouse effect, Biodiesel, Wind, Solar… these are the magic words that the press uses to fill the media… and its pockets.
We must have the hybrid car, but nobody tells us how much it costs to change the batteries. The solar panel is mandatory if we have to redo the roof, but how much does maintenance really cost? Is it possible that a high-speed tunnel creates so much noise and nobody says anything about the devastating wind turbines that disfigure our landscape? And all these pseudo-alternative sources don’t have the sole effect of increasing the extraction of oil, increasing pollution, and the gain of some caliph?
And all this is called Green Economy!!!

What should the E.cut technology be called then?
Few machine tools have similar characteristics.
1) Low current consumption, max 3 KVA
2) Use natural water with completely biodegradable vegetable additive
3) Maximum material utilization thanks to a cut of only 0.2 mm.
4) Recovery and reuse of scrap up to minimum size, (see expensive or precious metals)
5) No swarf

.

These topics are only one part, the most obvious, to apply the word Green Economy to E.cut.
Actually, it is the technology itself that is revolutionary, and leads to unexpected gains and savings. It is erosion cutting technology at such a low cost (20 times less than wire erosion) that it is green.
It is the possibility of making pieces with radically different cycles, at an incredibly lower cost than Green.

E.cut allows you to “DO” Green Economy,
in your company,
and the gain, of putting it

in your pockets!

.

These small teeth, made of particularly hard material, should be obtained from an ad hoc profile, from which the pieces are cut.
The problem is that there are no quantities!
The cost of the drawing line, and a minimum of production of drawn parts would be prohibitive to produce a few hundred of these pieces.
The precision required makes the cost of obtaining them from machining very high. Laser and water cutting do not guarantee tolerances and roughness, so the possible solution is wire erosion.
Any conventional wire erosion has a cost of operation, (wire, distilled water, ion exchange resins, filters, and … maintenance) ranging from 10 to 15 euros / hour.
The cost of each piece is therefore about one euro. 500 pieces cost 500 euro.

cut has an operating cost that does not exceed 40 cents per hour, so, in abundance, each piece costs less than 5 cents. 500 pieces cost 25 euros!

The difference in cost is not, however, the only advantage.
With Ecut, the “open” machining, i.e. not in a immersed tank like conventional wire erosion, makes the fastening equipment extremely simple, inexpensive and easy to place. You can do this during the day, and leave the machine “in production” at night!
Another important aspect is that the cost does NOT depend on the quantity to be carried out. Producing 10 or 5000 teeth has a cost per tooth that is always the same.
The economic quantity of production is 1! So do not put under at least 500 (or 5000), otherwise they cost too much.
If you need 224 pieces, produce 224, not 5000!

Let’s beat the Orientals with their weapons!

E.cut is not just a machine tool. The E.cut “concept” makes it an authentic Jolly in mechanical processing.

“Concept”, because the cost/performance ratio makes it possible to use a technology that has been known and appreciated for a long time, wire erosion, in sectors where high cost precluded its use.

Mr. Taglietti, owner of ATF Stampi, would never have bought a wire erosion. The purchase and operating costs were too high for his needs to occasionally cut shapes on thicknesses up to 300 mm.

The Ecut “concept” of always using the same wire, and its simplicity of construction make the machine economical, and “possible”.

At IRTI, the Facchini family, ancient breed mechanics, decided to purchase the machine as soon as they saw it. Without knowing exactly what it was for. The “concept” of a stitch that cuts any metallic material, with any profile, inserted directly in the machine by the CAD, has been perceived, “carpito” on the fly. A few days after the installation they cut keys for which the delivery time was long, or threading tools whose purchase cost was dozens of times higher!

At first glance it would seem that in a lathe, especially in an automatic lathe, there are few or no reasons to have an Ecut, a wire erosion. We thought so too, until Mr. Cottarelli made us change our mind, buying one.
With over 60 automatic lathes, sliding headstock lathes, multispindle lathes, numerical control lathes, with machines over 40 years old, and very modern machines, the CTA of Gordona (Sondrio), well represents the hundreds of companies of this type scattered in Italy.

“No, we do bar turning, we’re not mold makers. We don’t need wire erosion. That’s the standard reaction.

Mr. Cottarelli instead wanted to see Ecut at work, and asked himself what he could do with it!
With a disenchanted eye and free from conventions he considered this wire that in 2 tenths cuts any metallic material of any hardness. And verified the cost of the machine and operating cost, he decided to buy it.
Today he has relegated to the attic some sophisticated sharpening machines with which he built and resharpened tools. The advantage, especially for profiled tools, is incalculable.

With Ecut, directly from the DXF profile of the workpiece he gets the tool. Perfectly stripped in all walls, not just on the front. Ready to go into the machine… with 0.1 radii, unthinkable with grinding wheels.

No more grinding wheels, profile projectors, Diaforms and the like. No more dust, no more people spending hours sharpening… and burnt fingers.

One of the highest costs in the company has been drastically reduced!

The ease in generating profiled tools at a negligible cost allows the use of old and abundantly depreciated machines for machining operations performed by sophisticated numerical control machines.
These chess machines, for example, are produced with a normal parallel lathe with profiled tools, at practically no cost!

The contraction in quantities today often makes the cost of tools disproportionate. Threads with special steps involve the purchase of “boxes” of 10 inserts at a cost of hundreds of euros. Often these inserts are no longer used … and remain in stock!

With Ecut the tool can be quickly obtained from a simple brazed, or from a standard insert, at a negligible cost, in the quantity strictly necessary, and… resharpened in an instant.

E.cut mini also for maxi pieces

Ecut works without an immersion tank. The washing is by gravity, and at low pressure, so the pieces can be even considerably larger than the work table. The following film is an example.

This piece, over 1400 mm long, requires a 30×120 mm slot on the 150 mm thickness. The length required an erosion machine of considerable size, and therefore extremely high hourly cost. Not only that, but all the holes had to be hermetically sealed to prevent the deposit of eroded particles on the threads, and the certain and rapid rusting.
Ecut uses water with an emulsion that does not involve oxidation.

The high speed of the wire flow and the absence of high pressure liquid eliminate the barrel effect that appears on high thicknesses with conventional WEDMs.

The cost of working with Ecut is so much lower than that possible with conventional erosion that the savings achievable with the execution of a few dozen pieces has allowed the purchase

The accuracy guaranteed by E.cut is +/- 0.015 mm. A precision into which most of the machining operations fall.

Almost always a precision of this type is the result of roughing and finishing operations. Even in the case of conventional wire erosion, when the thickness of the wire exceeds 100 mm, the “barrel” effect comes into play, so that in the central area the cut is sometimes a few tenths wider. A revision is therefore necessary.

E.cut, thanks to its wire reuse technology, allows such a high sliding speed that the barrel effect disappears, so that with a single pass the cut is perfectly tailored. Dimensional and geometric.
The thickness of the cut, (from 300 mm. of the smallest to 800 mm. of the largest), does not affect the precision at all,

In the figure to the side, the 330 mm high bushing requires a 12 mm wide by 8 mm deep groove, and the result is within a hundredth.
No
tool, no tools for gripping, very simple program.

Beyond the pure cost, which is not real with E,cut, the difficulty that a similar process presents, often discourages the designer, and when it is not possible to do otherwise we go with wire erosion. Machines that work so thick are not, however, in the possession of many, and the cost becomes very high. Often prohibitive.

The incredible precision/cost ratio of E.cut opens up new possibilities already at the level of design of the pieces.

ZABER 50 years at the forefront, … and unconventional choices !
( click here to see the ZABER website )

Yes, because when Mr. Zaro and Mr. Bertolli, the two partners, more than two years ago took the decision, among the first in Italy to buy an E.cut, and one of the biggest, the skepticism shone through among the collaborators.

But 50 years of iron do not flow at all in the veins, and lead to a capacity ‘of analysis free from conditioning and clichés.

In the face of processes that had always been carried out in a certain way, Ecut represented something completely new on paper.
Keys on large pieces, high and narrow square holes, internal teeth on large bushings, were pieces already ‘previously performed, and of which we knew times and difficulties’. Ecut’s decidedly limited cost also made the decision less “heroic”.

Confirmations arrived in a few months, and as soon as the machine started to be “full”. a decision has been made to buy another one!
The biggest one in production!
An Ecut 120 with working strokes of 1600×1200 mm, a cutting height of up to 800 mm, and a load capacity of pieces up to 3000 kg.

The economic commitment is a bit greater, but after two years of experience, after comparisons with “as before”, the choice was much less painful.
The possibility of carrying out even small operations, despite the size of the machine, favoured the decision to take the largest one.
Not needing the operator, with a single placement, from a large plate more ‘pieces can be cut, taking advantage of nights, Saturdays, and Sundays.

These two toothed crowns were becoming a problem! The module is not standard, and there’s no creator ready. As usual the customer needs it right away.
Of course, a CNC milling machine, and so on. But the thickness, and the particularly difficult material make the cost rise, to the point of making it almost prohibitive.
Wire EDM, therefore. But that who owns it is not there waiting for you,… and then a wire erosion has its price!

In many sectors there are not large numbers, and Ecut that between operating cost and depreciation cost does not exceed 3 € / hour is an unsurpassed solution.
If you are in competition with those who own an Ecut, you have no choice in such situations. He takes the order.

Forget the sterile clichés about Chinese living with a handful of rice. Look at the pictures next door. You’ll notice the dirt, which is what’s immediately obvious!
But there are only two people (two!!) who make 19 cars go, who work day and night. The cars, not the people. They do their 8 hours, like everywhere. Just think how much people here in Italy cost you!

Returning to the two crowns from which we started, the client arrived in the afternoon at 4 p.m., and at 9 p.m. his crowns were finished! The next morning he took them away!
Two hours and thirty minutes for the sixteen teeth with a diameter of 200 mm, with perfect geometry, cut without any burrs, and without superficial hardening!
If they had been ten pieces, even better! The smallest Ecut cuts up to a thickness of 300 mm. Then put one on top of the other, just one placement and for 30 hours the machine would have worked… alone.
The total cost is about 7,5 euro… but the customer was very happy to pay 50!

How much does a smear cost?

Often in production the nose is slammed with problems of apparent simplicity but underestimated in terms of cost.
The processing of thin tubes, whatever the material, but especially when expensive and valuable, makes it necessary to take precautions and care that increase costs.
Tubes of a few tenths of a thickness cannot be tightened without criteria, under penalty of deformation. Therefore, shaped pliers and special, special tools, and as such expensive, must be studied.
Cutting with conventional methods, but also with lasers, water, etc., always leaves burrs or micro burrs whose accurate elimination is almost always considerably more expensive than the cut itself.
If the cut is not straight, but has a profile, the use of shearing dies is necessary.

In the presence of large lots, everything is justified, but when there are no large quantities, the matter becomes complicated.
Electroresion has been used for decades to cut the tubes of hypodermic needles, but there, the high numbers have justified the use of special wire EDM machines.
Wire erosion cutting would be ideal. No need to tighten the workpiece, just keep it in place. No burrs, clean and precise cutting, and, given the very thin thicknesses, even short cutting times.
The problem is the high hourly cost of operation, and the fact that these machines are not mixed up with the production men. ( They are not all mould makers ! ).

E.cut represents a revolution.

The hourly cost of operation from 10 to 20 times lower than that of conventional wire erosion, the extreme simplicity of management, and even more ‘the ease’ of use within the reach of any worker, make it unbeatable adoption in these cases.

Incredible cut of 4 superimposed stainless steel tubes. Cutting practically impossible with conventional wire erosion, except with very low cutting speeds.

Of course, the latest generation of tools have often helped to solve the problem of machining difficult materials such as stainless steel, titanium, inconel, monel, kidney’, ecy…,….
The machining of alloys whose characteristic is to harden at the high temperatures developed by the cut, is still to be addressed with great care, because the mistakes cost dear, very dear, given the high cost of the material.

Wear, breakage, and therefore the cost of tools often affects in an unexpected way. The risks, and the “rognosis” of the processing of these materials leads to estimates that take into account all this, and therefore to high final costs, and to the loss of orders that would be interesting.

Wire erosion would be the ideal solution: no influence of the toughness and hardness of the material, absolute precision of machining, no broken or worn tools, no chips, but scrap resaleable at cost.
Unfortunately, the high hourly cost, (from 5 to 8 euros/hour of only operating cost!), makes it impractical to adopt it!

The working with E.cut represents in these cases a “magic” and revolutionary solution.

The hourly cost of less than 0.4 €/hour of E.cut is the basis of the “magic” that brings the cost of machining this piece to less than a tenth of the previous milling.
Precise, clean and burr-free. An impeccable solution.

The E.cut technology, with the possibility to cut thicknesses up to 300 mm already with the smallest machines, allows to revolutionize and to face in a totally new way the “process” to obtain certain pieces.

These could be the expressions of those who bought a Used Wire Erosion instead of an Ecut.

The irony is evident, but some simple considerations make the images very plausible.

The following table, allows to compare, in a single and synthetic given the reason.

For wire erosion are considered: wire, distilled water, ion exchange resins, filter cartridges, wear parts. The annual maintenance costs have been calculated as if the machine were new, while the risk with a used machine is much higher, and at higher costs.

For Ecut are considered: Wire, liquid/sap to be emulsified with normal water, wear parts, and routine maintenance. (practically non-existent for several years on new machine)
It is evident that considering a use of 3000 hours, (quite low value for an erosion, machine that operates day and night), the difference in cost of management is over 10,000 € / year.

Other factors must be considered:

1) The management of wire erosion is much more complex and demanding than the management of Ecut.

2) Ecut is more precise than used wire erosion.

3) The smallest Ecut cuts up to 300mm thickness. No wire erosion that cuts this thickness can cost, even if used, less than a new Ecut,

4) Ecut allows to overlap pieces to be cut, without suffering from the barrel effect.

5) Ecut does not work with an immersion tank, so it is possible to cut even large pieces.

6) Ecut technology does not cause surface hardening, nor does it trigger microcracks, allowing it to be used even in sectors where normal wire erosion is prohibited. ( Aviation ).

7) At the price of any used wire erosion, (in good condition), it is possible to buy an Ecut with the possibility of cutting, X,Y,Z, considerably higher.

Perfect and impeccable.

In front of a piece of this kind (about 60×40 mm x 4mm thickness) any good mechanic stops to reflect.

The first question you ask concerns the mind of those who designed it!

Once you have ascertained that this is the way to do it, you begin to think about how to do it. Work center, broach for the teeth of the hole, teeth of the half-corona,.. If then the material is difficult, or must be treated the matter becomes even more complicated.

In the end, only wire erosion remains. If you already have it, that’s fine, otherwise with traditional processes it’s a nice headache,

But with wire erosion, the cost is still high. The removal times are the same as they are, the placing times, with the need to respect guidelines and phases, too. If we put too many pieces one on top of the other to gain some time, there is the trap of the barrel effect, so the precision goes to be blessed …

If your competitor has an E.cut, he’ll almost certainly take the order!

With E.cut you can easily “pack” about fifty pieces and cut them all in one go.
Since there is no beating effect, from the first to the last will be in the couple of hundredths of tolerance.

Add that the hourly cost of exercise is more than ten times lower, so even if you go over it again to bring the roughness up to 0.8 Ra, the final cost will still be extremely low.

I

I’ll cost you.

If you make your customer pay half of what it would cost him with a conventional wire, he’s very happy, and you still earn a lot of money!

Probably that’s why those who own an E.cut don’t care much about letting them know!

The execution of the housings of the electronic boards in the baskets (racks), would benefit greatly from the processing with wire erosion. However, this process is not suitable for designers of aeronautical materials, and for anyone who has to produce parts that will be subjected to extreme stress and risk of breakage.
For many, hostility is considered unfounded, but in reality there are reasons. In fact, the ellectrosion, because of its principle of operation, causes surface hardening, and very dangerous microcracks because ‘trigger of possible breakage. The phenomenon is well known by mould makers and by those who produce dies for extrusion.

The E.cut technology is basically that of wire erosion, but the peculiarity of being able to slide the wire from 60 to 100 times faster, allows to increase the number of discharges per second, and decrease the intensity. The result is a much lower material “stress”.

In-depth laboratory analyses carried out in one of the most famous Italian research and testing centres for materials, found on the same material (ERGAL 7075) “… the presence of a slight deformed/concred layer…” for processing with conventional wire EDM, and instead “… the absence of microstructural alterations…” for processing with E.cut.

The possibility of running the wire so fast is given by the fact that the wire is not thrown away, but is wound/unwinds on a drum, being used for a very long time. The cost of the process is drastically reduced.
Even if the problems related to cracks and hardening are not relevant, the cost of making a basket is reduced with E.cut from 10 to 20 times compared to conventional wire erosion.

The execution of profiles on carbide or diamond inserts has been carried out for years with wire EDM machines, especially for quantities that do not justify the production of inserts already profiled by sintering.

In the furniture, windows and doors sector, and in general in the woodworking sector, the need to frequently change the models produced and to insert new ones requires tool manufacturers to be quick in meeting their requests, which are also increasingly limited in quantity.

The adoption of wire erosion has therefore been for many an obligatory choice, and often the purchase of a used machine has solved the problem.

But, in addition to saving money on purchase, compared to a new machine, a conventional erosion machine still has a cost of ownership, especially if old, considerable.
Among distilled water, filters, ion exchange resins, wear parts, and, most important of all, brass wire, it goes from 4 € / hour to 8 € / hour and beyond. So the daily cost ranges from 50 to 150 euros per day depending on the hours of work.

With E.cut the operating cost never exceeds 0,4€/hour!

The bill is therefore soon made. The daily cost, even in the case of continuous work of 24 hours, does not exceed 10 euros.
There are no tricks or mysteries. The simple fact of not throwing the wire, (see on the site the technical and functional features), allows you to slide it at 600 m / min instead of 6mt / min. No more need for distilled water, filters, resins, or other.

Paradoxically, if the competitor has E.cut, it has lower prices, earns more, and…  you take the market!

For example, the blades of press brakes, or the blades of planes for wood.
Cutting to size pieces of workpieces that have already been tempered or even hardened in some places is a considerable cost.
Cutting with abrasive disks is not precise, and the cutting area is tempered. It is therefore necessary to leave a certain amount of metal, with the duplicate purpose of measuring by grinding, and remove the part found.
The cut is fast, the grinding a little less, but almost always the two phases are carried out manually, and require qualified personnel, despite their simplicity.

Wire erosion is often used, which has the advantage of not letting the material come to light, and of obtaining a precise and geometrically accurate cut. The hourly cost of operation, (wire, demineralized water, ion exchange resins, filters, etc..), greatly limit the use. Only in case the machine is out of work, closing the eyes on costs, is it used for this purpose.

E.cut represents a revolutionary solution! In addition to the characteristics of a wire erosion machine, it has some notable advantages.

-Do not work by immersion, so the pieces can escape from the pallet.
-The maximum thickness of cut is 300mm already from the smallest models, allowing to overlap more blades.
-The hourly cost of operation does not exceed 0.4 €/hour, compared to 4 €/hour of the cheaper conventional wire erosion.
-Management and maintenance are extremely simple, and do not require specific skills.
-The purchase cost of an Ecut is 4 to 8 times lower than conventional wire erosion.

Machines that can cut up to 800 mm in height are possible.

Digging a plate to get the seat of dowels is a basic processing in the executions of moulds.
Of any kind they are, for sheet metal, plastic, or die-casting, the execution of extensive quarries, especially when the depth ‘begins to become high, engages large machines and expensive tools.
Often they are not sophisticated and expensive machines, but for this reason they need the presence of the operator. And the operators themselves are almost always expensive.

The decomposition into two plates, one at the bottom and one for the quarry, allows the use of wire erosion, but only by having one, there, ‘firm and unused.
In many companies, where there is wire EDM, sometimes it is done, without paying too much attention to the costs, and with many limitations.
The dimensions of the plate are not always in the machine tank.
If the thickness to be cut is more than 150 mm, the machines that can process it begin to decrease, and those that can do so cost more.
The hourly cost of operation, (brass wire, distilled water, resins, filter cartridges, etc.), is justified for work with high demands for precision and finish, but for the execution of a simple quarry, they are often prohibitive.

E.cut does not work by immersion, so the plates can also “come out” of the pallet.
The maximum thickness that can be cut starts from 300 mm for the smallest machines, up to 500 / 600 mm for the largest ones.
The wire is not “disposable”, and flows at a speed of 100 times higher than a normal wire erosion. No demineralized water, no ion exchange resins, no filter cartridges are needed.
The hourly management costs are 10 times lower, not exceeding 0,40 €/hour.
At a speed of more than 600 mt/min, against the 8 mt/min of a wire erosion, the wire “cleans itself”, eliminating the annoying barrel effect.
The walls can be parallel, or inclined, and with the same simplicity with which a rectangular quarry is carried out, quarries can be carried out with any profile.
The contours to be cut can be generated directly on the machine through the CAM part of the CNC, which is entered directly in DXF format.

The difficulties in machining spring steel by removal are well known, and always faced with reluctance.

When it is absolutely necessary, usually when samples or small series of pieces are required, the final costs are high and the results unsatisfactory, both because of the difficulty of maintaining precision, and because the machining operations (drilling, milling, turning, ..) “stress” the material to such an extent as to compromise the final functionality.

The solution often adopted is cutting with conventional wire EDM. Often it is the only solution but the cost limits its adoption considerably.

Ecut technology opens up completely new possibilities.

The extremely low hourly operating cost (more than ten times lower than that of conventional wire EDM) is the most important factor.

If in fact cutting a pack of 50 discs of 50mm diameter with conventional wire erosion costs (*) around 60 euros, with Ecut does not exceed 6 euros!

Two other factors are important.

The first is that Ecut technology does not cause surface and micro cracks (absolutely forbidden in various sectors, such as aeronautics, X-rays, etc.) which are particularly harmful in the case of springs.

The second is that even the smallest model of Ecut can cut thicknesses up to 300 mm. Clearly, the springs are only a few millimetres thick, but such a large thickness of cut allows you to work “columns” of hundreds of pieces at a stroke, further reducing the cost, and also making interesting the execution of a few thousand pieces without having to deal with the construction of moulds.

(*) hourly cost of operation = cost of depreciation + tool cost + cost of wear and tear parts and consumption + cost of maintenance

The pieces in the picture are copper contacts. In this case, they must not be produced in such quantities as to justify the investment in a punching tool.
Not only that, but the sampling of a few dozen pieces if performed by conventional machining, cutting and milling, presents difficulties ‘that make it significantly increase the price.
The two cuts separating the contacts had to be of maximum width of 0.2 mm, so even the machining with conventional wire erosion would have had in addition to the already ‘high cost, an additional cost due to the need’ to use a non-standard wire to obtain these slots, with all time to replace wire guide bushings, as well as the waste of wire of less than 0.2 mm in diameter, non-standard, therefore unlikely to be used in the future.

Wire erosion processing was still the only valid method, especially for sampling, and despite the high cost, because it was free of burrs, very expensive to remove on copper after removal processing, and absolutely prohibited in contacts of this type that must support high electrical voltages. ( burrs would be triggered for voltaic arcs ).

E.cut has represented the ideal solution for several reasons that can be traced back to a cost of the pieces that has resulted in a few euros per piece, well over 10 times less than with conventional wire erosion.

The wire normally used by E.cut is in fact 0.18 mm and causes a cut of 0.2 mm, therefore perfect for the required need. The required sampling of about thirty pieces was obtained in one go, superimposing all the copper plates, so the piece time was a few minutes.

Considering then the hourly cost of management of E.cut, which does not exceed 40 euro cents / hour, and the possibility to work already ‘with the models’ smaller thicknesses of 250 mm, even the production of a few thousand pieces’ was infinitely more’ convenient than with any other method.

The price of the machine, extremely low compared to a wire erosion, allows the purchase even if the use is sporadic and not continuous.
The availability of the new technology in the company then leads to the use of the system for various other processes, which were first carried out by third parties.

This is the profile that must be obtained in a sliding bronze sleeve.
It’s a bit of a special sleeve.
It is 500 mm high, and the hole is 250 mm.

The 0.18 mm molybdenum steel wire generates a cut of 0.20 mm. Tolerance is + – 2 cents, the profile was made with a CAD, and imported directly from DXF. Compensation has been added via the CNC.
The roughness is more than satisfactory, a blow of cloth, and so on.

Maybe you could do it with a stapler, but what a stapler! And what a cost!

500 mm high, the maximum for this E.cut 63, but parts up to 800 mm thick can be cut.

P.S. The proceeds from the processing of 6 of these pieces has paid the entire machine