Teeth and keys

Teeth and keys

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….

Evolution or Revolution?

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.

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At a cost…

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

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

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

The leaders of 3D printing adopt E.cut.

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

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

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

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

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

Genesi is the partner for Europe.

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