Precision machinist opts for Mitsubishi

In the face of shrinking demand for rubber injection moulds, AMB near Paris has been adding precision prototypes and mechanical components for a wide variety of industries to its portfolio.”

To aid this transition, the company began searching for a new wire EDM, as Jacques-Henri Miguet, second-generation managing director, explains: “We needed a new machine because our existing wire EDM from another manufacturer was unreliable and caused excessive maintenance costs.”
Initially there were discussions with three different suppliers, but the choice quickly narrowed down to the Mitsubishi Electric MV1200R offered by local agent Delta Machines. One important reason was that the system accommodates a working height over 200 mm.
Ultimately, a wire EDM system type MV1200R was purchased along with an EA8S die-sinking EDM system.
“Our Mitsubishi wire EDM machine works perfectly and delivers everything we expected of it,” says Miguet.
The MV1200R achieves an accuracy of 1/100 mm when used with wire diameters from 0.1 to 0.25 mm, usually with two passes to achieve the best possible quality. In two-shift operation and with an average spool life of 20 hours, jobs can usually be planned so that the next change falls within an employee’s working hours and the machine runs largely around the clock. In this context, the automatic re-threading of the wire after a breakage, even in the narrowest kerfs, is also very useful.
“If I should ever need another EDM system, I know exactly who to contact,” says Miguet, summing up his experience.
For further information www.mitsubishi-edm.de

Output climbs

Manufacturing output across the UK increased significantly in May from its record low level as factories started to emerge from the coronavirus lockdown, according to figures from the latest BDO Business Trends report.

BDO’s Manufacturing Output Index jumped by 16.58 points to 69.55 in May, regaining around half of the losses sustained between March and April as manufacturers benefited from the easing of UK lockdown measures. Kaley Crossthwaite, Partner at BDO LLP, say: “Output remains drastically below where it would be in ordinary times, but the latest readings suggest we have passed the rock bottom of this crisis.”
For further information www.neweconomy.bdo.co.uk

Cost-effective tool grinding and erosion

Walter has announced two new entry-level machines for re-sharpening and manufacturing a wide range of carbide, PCD and HSS tooling in the most cost-effective way.

These include the ‘two-in-one’ eroding/grinding Helitronic Raptor Diamond, which is designed for PCD tools up to 400 mm diameter and 270 mm long (also end face operations).
The machine can be configured with, for instance, a Walter Top Loader (which accommodates up to 500 tools), glass scales, torque drive on the A axis, wheel probe and manual support steady rest.
Walter’s ‘two-in-one’ Helitronic Raptor Diamond, which uses an HSK interface for electrode/grinding wheel mounting, also features an 11.5 kW spindle, while its Helitronic Tool Studio software embraces integrated erosion functionality for the fast and easy programming of ‘what you see you can grind and erode’.
In addition, the machine boasts Fine Pulse Technology, a Walter innovation that is said to set new standards in terms of PCD tool surface and edge quality, as well as process reliability and speed of erosion. Fine Pulse Technology is the result of progressive improvements to the machine’s generator, as well as the erosion software.
With Fine Pulse Technology, there are marked differences to PCD tools of standard grain type that have been eroded by other machines. Indeed, the differences can be seen with the naked eye – the surface finish is like that of a polished (ground) tool and even coarse-grained PCD
types can be fine-finished with perfect surface qualities, reports the company.
Fine Pulse Technology is the result of progressive improvements to the machine’s generator, as well as the erosion software.
For further information www.walter-machines.com

Cutting-tool plant relies on Vollmer

Cutting-tool manufacturer Mapal opened its Fountain Inn, South Carolina plant in 2013 to complement the company’s existing US headquarters in Port Huron, Michigan, as production manager John Schuck recalls: “In 2013, we were sweeping the floors and waiting for the first machines to arrive, one of which was a Vollmer QWD750H wire-erosion machine with a 12-station tool loader. Our immediate growth noted an additional two QWD750H machines arriving in spring 2015.

“From day-one, our ambition and plan for this facility was to run ‘lean and unmanned’ production wherever possible, and the 12-station Vollmer QWD750H wire-erosion machines have supported this philosophy,” he adds.
As the company ramped-up production, it exponentially increased its investment in wire-erosion technology. For instance, Mapal acquired more Vollmer machines in 2018. Succeeding the Vollmer QWD series as the next-generation technology, Mapal took delivery of two new Vpulse500 machines in March 2018.
“We were really pleased with the performance of the QWD750H models, but the new Vpulse500 takes it to a new level,” says Schuck. “Vpulse500 machines incorporate a new erosion generator that is far more efficient than the QWD models. The new erosion generator and the new control format are optimising our productivity, giving us 25-30% cycle time reductions over the previous machines, while generating improved surface and edge finishes. Furthermore, the CNC control and software has been enhanced for greater ease-of-use and operator friendliness.
“No doubt more Vollmer machines will follow as we continue to grow,” he adds. “From a staff perspective, part of our growth trajectory will see us start an apprenticeship programme this year and what better environment for apprentices to learn than in a new factory with state-of-the-art machine tool technology from Vollmer.”
For further information www.vollmer-group.com

Wire EDM with Spark Track

The AgieCharmilles CUT 2000 X wire EDM has been upgraded by GF Machining Solutions to feature the latest Spark Track technology and an IVU (integrated vision unit).

Spark Track technology, with its intelligent spark protection system (ISPS) that provides information about spark distribution on the wire, allows users to avoid wire breakage regardless of the machining conditions, as well as reduce part defects and simplify machine operation. Wire oscillation, varied heights and tapered surfaces are among the common problems resolved by Spark Track technology. To achieve optimum results, the discharge distribution along the wire must be as uniform as possible.
Using IVU Advance, operators can reduce set-up times, check reference points without a measuring machine and correct machining errors. A CCD camera reduces the need for an operator’s presence.
Having this on-board measurement system to analyse light intensity variation allows the detection of edges, which saves costs and facilitates closed-loop manufacturing. At the same time, multiple measurement systems are available for part control and set-up, along with automatic shutter and part-cleaning solutions.
The CUT 2000 X’s Vision 5 software interface allows manufacturers to optimise production, achieve flexible job management and improve quality and productivity, says the company. Furthermore, Vision 5 simplifies last-minute machining sequence modifications and allows for special actions to be introduced directly inside the job.
Another innovation is open guides on the automatic wire changer (AWC) that permit manufacturers to use a combination of different wire diameters between roughing and finishing, thereby reducing machining time for small and complex geometries, resulting in up to 32% more productivity. Additionally, two 25 kg wire spools are available that eliminate the need to modify the wire circuit when switching wires.
For further information www.gfms.com