FEATURE ON EDM

New wire EDM series improves accuracy and flexibility

For many years, manufacturers accepted that no single wire EDM machine could excel at every application. Some prioritised speed, others surface finish or taper accuracy. With the introduction of the CUT X 350 and CUT X 500, GF Machining Solutions says it is challenging that assumption.

Developed and built at the company’s Losone, Switzerland facility, the CUT X series is available in two sizes to accommodate workpieces up to 800 x 550 x 250 mm (CUT X 350) and 1050 x 700 x 250 mm (CUT X 500). Both models are engineered for high precision, combining optimised machine mechanics with an advanced thermal management concept. A sealed cabinet and controlled airflow maintain stable internal temperatures, while heat sources are isolated from critical components to minimise the influence of ambient fluctuations.

An array of internal and external sensors feeds data to the CNC, where an AI-driven algorithm predicts potential thermal deformation and compensates axis positioning in real time. The result is consistent micron-level accuracy, even during long machining cycles.

Flexibility is enhanced by interchangeable open and closed wire guide cartridges, which can be changed and aligned in less than 15 minutes. Open guides suit straight or low-taper cuts, while closed guides deliver higher accuracy and surface quality for tapers up to 30°. Additively manufactured heads improve flushing efficiency and increase cutting speeds.

The UNIQUA HMI, featuring a 19-inch vertical touchscreen, provides intuitive control and supports legacy file formats.

Further productivity gains come from automatic wire changing, dual wire circuits, intelligent spark protection, integrated probing and automated slug management, ultimately enabling reliable, lights-out performance across a broad range of EDM applications.

More information www.gfms.com

Ultimate reliability: 35-year-old wire EDM still in use

When Kress Funkenerosion was founded in 1990 in Mühlhausen, near Nuremberg, its future rested on a single machine: a FANUC Tape Cut W2. As a young tool- and mould-making subcontractor serving demanding sectors such as automotive, aerospace and medical, uptime was critical. The brief for that first investment was straightforward: deliver high-quality wire-cut components with absolute reliability.

More than three decades later, that same machine remains in daily operation, a testament to the durability and engineering philosophy of FANUC.

The machine’s longevity set the tone for the company’s future direction. Impressed by consistent performance and minimal maintenance requirements, Kress Funkenerosion standardised on FANUC wire EDM technology, investing in a further 12 machines over the years.

The most recent additions are two FANUC ROBOCUT α-C400iC models, which provide both precision and versatility. Managing director Michael Schander reports that tolerances of ±3 µm are achieved with ease, supported by reliable automatic wire threading in under 10 seconds. Yet, for Schander, performance figures tell only part of the story.

“What really sets FANUC apart is the build quality,” he says. “The last service call I remember was over six years ago. That level of reliability is exceptional.”

Today, all wire EDM machines on site are FANUC models, forming the backbone of the company’s ISO 9001-accredited operation. For founder Gerhard Kress, the decision remains clear: “The first machine I bought in 1990 is still running. After more than 30 years of experience, I see no reason to change.”

More information www.fanuc.eu

Sodick wire EDM powers automotive excellence

Set against the backdrop of Northern Italy’s industrial heartland, Meclostampi Group has specialised in progressive toolmaking since 1971. Founded by Cavaliere Antonio Canobbio and now led by Valter Canobbio, the company serves demanding automotive customers with a clear philosophy: quality first. That mindset has driven its continued investment in EDM technology from Sodick since 1988.

“Our parts are only as good as the machine that produces them,” says Canobbio. “Choosing the cheapest option is short-sighted, and the same applies to service.”

Operating from a 7000 m² facility in Lomazzo, Lombardy, and employing more than 80 skilled staff, Meclostampi partners with RF Celada SpA to deploy advanced Sodick wire EDM technology. The close collaboration ensures high levels of machine performance are matched by responsive technical support.

A key advantage has been Sodick’s ability to overcome the long-standing challenges of machining carbide.

“In the past, carbide created surface issues on other machines,” explains Canobbio. “Sodick solved this issue years ahead of its competitors.”

The result is superior surface integrity, greater tool life and enhanced process reliability.

Meclostampi’s Sodick fleet includes ALC 600G, SLC 600G and AG60L models equipped with linear motor drives, advanced generators and intelligent control systems. These technologies deliver micron-level accuracy, smooth surface finishes and consistent positioning performance – critical factors in the production of progressive, transfer and deep-drawing tools for automotive applications.

Reliability is equally important, as Canobbio confirms: “I don’t remember a stoppage for maintenance.”

With in-house stamping presses ranging from 250 to 6000 kN, Meclostampi can validate tool accuracy and longevity under real production conditions.

“Speed, accuracy, reliability and flexibility define quality tooling,” he concludes. “Investing in the right technology ensures we remain the best partner for our customers, today and in the future.”

More information www.sodick.eu

Birds Precision flies high with Sodick wire EDM

Nuneaton-based Birds Precision Engineering has recently invested in a Sodick AG 600L wire erosion machine from Sodi-Tech UK, marking a significant advance in the company’s capabilities and service offerings. This strategic investment represents the latest chapter in the evolution of a business that has been growing steadily since its inception over three decades ago.

The story of subcontract CNC machine shop Birds Precision Engineering began in 1991 when Chris Bird established B&C Engineering in Nuneaton. What started as a sole trader operation quickly expanded, necessitating a move to larger premises. As demand grew, the business relocated and transformed into the name Birds Precision Engineering. Chris’s son, Tom Bird (pictured), joined the company and immersed himself in all aspects of the operation, eventually becoming managing director in 2023.

The latest advancement came earlier this year with the acquisition of a Sodick AG 600L wire erosion machine from Sodi-Tech. This investment was driven by practical business considerations, as Tom Bird explains: “We’re predominantly a subcontract CNC machine shop and focus mainly on the special-purpose machine tool industry. We invested in the wire eroder because, in the tooling industry, there’s a lot of complex components with tight tolerances.”

The Sodick AG 600L is a high-precision, linear motor-driven wire EDM machine utilising advanced linear motor technology to achieve remarkable precision, with accuracy on all axes (X, Y, Z, U, W) of ±0.001 mm.

This level of precision is crucial for Birds Precision, as Bird notes: “Customers are always after accuracy. The components that we’re machining are getting tighter and tighter on tolerances every time we see the drawings. It’s a major factor, and this machine helps to set us apart as we always guarantee to hit those tolerances for our customers.”

More information https://sodi-tech.co.uk/

21% faster processing speeds with Turbo Tech

Turbo Tech cutting technology, a standard option on new AgieCharmilles wire EDM machines from GF Machining Solutions (now United Grinding), is said to deliver faster processing speeds with no compromise on quality (part accuracy and surface finish). In a recent benchmark test cut conducted by GFMS engineers, Turbo Tech cutting technology was pitted against the company’s ‘Speed Tech’ cutting technology in a timed trial – the objective being to find out which would deliver the fastest processing speeds.

The cutting process undertaken involved two CUT P 350 Pro wire EDM machines, simultaneously machining an identical punch die component using AC Brass 900 wire (0.25 mm diameter). The punches were both cut from 30 mm thick steel, and the requirement was to achieve a 0.45 µm surface finish.

With the first CUT P 350 Pro, the ‘Speed Tech’ setting was selected from the machine’s UNIQUA iHMI control, with the ‘Turbo Tech’ setting deployed on the second. The cutting process, involving a main cut followed by three trim cuts, was timed for each, with the part being machined using Turbo Tech taking 30 minutes to complete as opposed to 38 minutes with Speed Tech.

Says Martin Spencer, GFMS UK managing director: “In this relatively straightforward test, the processing speed of the part being machined using Turbo Tech was 21% faster. For more complex parts this can be increased to over 40%, demonstrating that Turbo Tech delivers increased productivity and improved accuracies, whatever the flushing conditions and irrespective of the wire in use.”

More information www.gfms.com