Evolution or Revolution?

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

The years go by

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!