How does a 70% reduction in Wire EDM operation costs Sound to you?


Novicut M-II New series

The price of a wire EDM machine is nothing compared to the cost of wire over the life of the machine. “Wire is the single highest expense in operating a wire EDM.

One of the highest operating costs for any wire EDM is the cost of the wire the machine consumes during a cut. Although wire consumption rarely appears as a topic of concern for most wire EDM users, the financial benefits of owning a Molybdenum wire-cutting machine can be critical to a manufacturer’s bottom line.

EDM brass/copper wire, at its current cost of approximately 10-15 Euro a kilo, is the single highest cost related to the use of WEDM technology. The faster a machine unspools wire, the more it costs to operate that machine.

On average, most Copper/brass WEDMs unspool wire at a rate of 750 grams to 1.1 kg per hour. And although these higher rates can be reduced by slowing the unspool speed, manufacturers must then deal with increased breakage of the wire with additional adverse effects to speed, accuracy and surface finish. Under these unreliable conditions, increased cycle times and maintenance can oftentimes negate or even surpass the cost saving of slower wire feeds.

Cutting this high operating cost by 40 percent to 50 percent equates to an EDM wire saving value of about €8,000 to €10,000 per machine, per shift, per year! However, if this cost saving in consumables is offset by high maintenance costs and lost production time, there is no advantage. The ability to improve EDM wire saving while increasing productivity through reliability can have a significant impact on overall profit.

Investing in a Novicut M-II wire EDM will allow you to regain control over your EDM department and generate good profit.  When you are facing extended lead-times and part inconsistencies due to outsourcing and the unreliability of your older machines, then it’s urgent time to think on an investment that run unattended throughout the day, over nights and even weekends. We can ensure that quality will be again to your standards and saving money hand over fist on operational costs will be again in reach.

Although wire consumption rarely appears as a topic of concern for most wire EDM users, the financial benefits of owning a low-wire-consumption machine can be critical to a manufacturer’s bottom line. With the revolutionary Molybdenium wire cutting system with zirconium guiding wheels, you will be able to have savings of up to 70 percent in many applications while maintaining precision and surface quality (Ra<0.8µ).

Because Novick builds mechanical accuracy into these machines, the on-board computers are required to perform axis movement error compensations less frequently. This allows the control to address higher priorities, like activating Novick patented Fuzzy logic technology and performing the multitude of calculations required for it to work properly.

EDM wire, at its current cost of approximately €12-15 a kg, is the single highest cost related to the use of WEDM technology. The faster a normal machine unspools wire, the more it costs to operate that machine. For shops that run a WEDM for 2,000 hours per year, or one full shift, settings can experience about €10,000 each year in EDM wire saving per machine.

NOVICUT 350 M II

HIGH-SPEED EDM DRILLING

Do you want to expand Your Hole making Capabilities? Look into our Novidrill range


In need of producing Smaller, Deeper, More Precise Holes?

Demand for smaller, deeper and more precise holes produced as fast and as consistently as possible has created a need for more advanced, new Electrical Discharge Machine (EDM) drilling technology in hole making operations.

Here are some tips on how to select the EDM drilling system that will help your shop achieve these holes making goals.
  1. Look for an EDM system that is fast, reliable and simple to operate. It should have enhanced drilling capabilities for extremely small hole sizes, but at the same time maintain good surface finish quality and accuracy at greater depths. Considering some of to-day’s applications, it’s important to look for a system that can drill a 15-mm deep hole as small as 0,20 mm in diameter in hardened steel and at the same moment to be able to drill a cooling hole of 2,5 mm in diameter 250-mm deep in mould steel, and this with minute variations in size and straightness from its entrance to exit.
  2. Most experts recommend selecting an EDM drilling system that utilizes the latest in digital generator technology. Digital generator technology, gives EDM drilling machines more precise spark control. It is this functionality that also helps reduce electrode wear. For optimal productivity, the goal is to generate as many holes as possible or drill as deep as required using the least quantity of electrodes. Thus, the more a generator can help reduce electrode wear the better. Plus, less wear on electrodes allows them to cut faster and more accurately by eliminating the “bullet nosing” of their electrode tips.
  3. Seek out an EDM drilling system that can be operated by any person in the workshop, without any high-level programming skills. Simplicity is here the rule.
  4. High-quality surface finish capability is a must. A growing amount of shops now use EDM drilling machines for generating finished holes that will not require any secondary finishing operations.
  5. Keep in mind that uneven wear increases a drilling electrode’s tendency to “walk” off centre, resulting in crooked and angled holes instead of straight ones. Because they help reduce wear, Supper high pressure coolant/flushing system thus prevent such a scenario and contribute to producing straighter holes and ones that can be held closer to size from top to bottom. For instance, a 200 mm-deep hole drilled with a 1 mm electrode on a digital generator-equipped EDM system will vary in size from top to bottom, usually less than 0,025 mm.
  6. Find an EDM drilling system that provides control over heat-affected zones for generating surface finishes comparable to those typically attained using a wire-type EDM. Such surface finishes are possible only with a super high pressure coolant/flushing system with sufficient debit to take the heat immediately away from the working zone.
  7. High pressure dielectric fluid is one of the most important factors, which is usually supplied to the gap through the bore of tubular electrodes.  The use of a pneumatic intensifier pump results in drilling parts up to 50% faster and with lower operating costs as much as 40%! Pneumatic activated high-pressure pumps produce 30% more pressure than a standard water jet pressure pump, resulting in a 40-50% increase in productivity for many materials. Compared to a water jet pump, typical operating pressures uses 30% less water, 30% less power, and up to 50% less electrode consumption, resulting in a 40% reduction in operating costs. Being green with energy does not only spare the nature but also your wallet.
  8. Request a non conductive table of high precision, by preference Granite.  A work-table from granite offers big advantages:
    • You can’t drill into the table
    • table resist to corrosion of the dielectric liquid: doesn’t get rusty
    • keeps the super precision and guarantees a better flatness
    • parts cannot be welded to the table due to bad contact with table

Conclusion

Today’s technically advanced EDM drilling systems essentially put hole making accuracy in the technological hands of the machine tool. Modern EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality surface finishes.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Our Novidrill-400-II is offering on all these requested criteria a positive answer and this for a VERY attractive budget!

The Basics of High-Speed EDM Hole Drilling


High-speed EDM hole drilling was designed especially for fast, accurate small- and deep-hole drilling applications. Small holes that were once almost impossible to drill by conventional machine tools are now being performed with ease. With the capability of drilling through virtually any conductive material, the use of this technology is continually expanding.

Initially shops were using this technology specifically for start holes in wire EDM jobs. Because of this technology, workpiece materials are being sent out for heat treating prior to drilling the start hole. This removed two major problems: having to program, locate and drill the holes by conventional machine methods in the “soft” workpiece prior to heat treat and by heat treat the workpiece before drilling, all the stresses are being removed prior to the drilling process. As this process became more widely known, test burns were being done in more than just hardened tool steel; tungsten carbide, aluminium, stainless, titanium, brass and inconel were being tested. High-speed EDM hole drilling applications began to expand to mould and part manufacturing-injection nozzles, oil drain holes, hydraulic cylinders and dowel pins, as well as turbine blades, ball bearings and safety wire holes in hex nuts, to name a few.

The EDM Drilling Process

The process consists of using a precision tubular electrode (generally brass or copper) mounted into the drill chuck located on the “Z” axis and held in location on top of the workpiece by the ceramic guide. The top of the workpiece is located and the drilling depth is set. The electrode rotation is turned on and the deionized water solution, which is pressurized between 30 and 120 kg/cm2, is sent through the tubular electrode as a flushing agent. The power supply parameters are set-which normally consist of on-time, off-time, peak current and amount of capacitance. At this point, the discharge is turned on to begin the drilling cycle. At the end of the drilling cycle, the discharge is turned off and the “Z” axis is retracted above the workpiece.

Drilling Times

Drilling times are based on the hole size and type of material.

A few samples of possible speeds for reference:

Material Electrode Dia. Drill Depth Machining Time
Alloy Tool Steel 0,5mm 12,5mm 25 to 35 seconds
0,5mm 25mm 50 to 60 seconds
1,0mm 25mm 55 to 65 seconds
Tungsten Carbide 0,5mm 12,5mm 4 to 5 minutes
0,5mm 25mm 8 to 9 minutes
Aluminum 0,5mm 12,5mm 40 to 50 seconds
0,5mm 25mm 90 to 100 seconds
1mm 70mm 3 minutes

 

Observing the mentioned times explains why high-speed EDM hole drilling has become an alternate method to conventional machining in mould manufacturing. In addition, this method of drilling produces burr-free holes, which results in the elimination of secondary deburring processes.

Today, Novidrill 400-II can use distilled water/tap water as the flushing agent, which opens new and very economically application possibilities in the medical field. With continued improvement in this technology, more and more applications are being seen on the horizon-it has become a whole new method of manufacturing moulds and parts.

high speed edm

High precision wire cut at very low cost with the new Novicut M-II line


NEW Novicut M 650-II precision and accuracy wire cut test

Executed: 2017-november

Material: D2 Tool Steel | 1.2379 | X153CrMo12 | SKD11

Cold Works D2 tool steel is a high carbon, high chromium tool steel (12% chrome) with extremely high wear resisting properties, heat treatable to 60-62 Rc

Electrode : Wire of 0.18mm, Molybdenium wire 99.8%


Results :

  • Average Surface roughness : Ra = 0.76 µm
  • Pitch accuracy : 14µm
  • Shape accuracy : 9 µm

 

Procedure :

  • Multi-cutting function 4 cuts
  • Best roughness Ra<0.68 µm
  • Worst Roughness Ra<0.78 µm
  • cutting speed hit 315mm2/min at highest wire speed at first cut.

With the new advanced and patented pulse power eco generator specific for molybdenum we get much lower loss of wire (electrode wear). The diameter of a 0.18 mm wire, reduced with 0,007mm in 200.000 mm2 cutting (5 shifts of 8 hour working). This keeps the precision of the each cut at the lowest cost available!

novidrill EDM drilling

Chosing EDM Drill Electrodes – Novidrill 400-II


At Novick, we believe in trust and collaboration when dealing with our customers. Collaboration includes the responsibility to keep our customers well informed, as a customer that knows the strengths and weaknesses of their electrodes stands to gain time and money. There are many different applications that call for EDM Small hole drilling, and one electrode’s weakness in one application may be a strength in another. This and all of the other different variables encountered in EDM—such as workpiece material and machine settings—can make it difficult to choose the right electrode.

With the wide array of electrodes available on the market, you will be sure to find one that fits your particular EDM machine or equipment. EDM drill Electrodes doing well on your small hole EDM machine depend on two simple variables:

  1. The type of material that the electrode is made of—brass, copper, or tungsten carbide.
  2. The type of flushing hole or the desired internal diameter of the electrode. This is either a single hole diameter with no other internal walls or is a multi-channel type internal hole with multiple walls throughout the length of the electrode. Some electrodes dispense with the internal channels altogether. These are rods.
  3. Let’s first discuss the main two types of EDM tubing material: brass and copper. 97% of all applications for EDM electrode hole-popping involve either brass or copper electrodes.

Brass Electrodes

Brass EDM tubes are used on the largest variety of electrically conductive materials and metals to small hole drill. If you are not quite sure which electrode material to start out with, brass is probably the best bet. Due to the molecular composition of brass, it will remove material at the fastest rates when applied to certain alloys, tool steels, stainless steels and rare metals.

Brass is fast at the expense of wear rates. Brass electrodes tend to wear out much faster compared to copper electrodes at the point of spark contact with the workpiece, and this should be taken into consideration on long running hole burns or EDM holes that are very deep. This fast wear rate becomes a particular problem when attempting to burn through stubborn materials such as carbide or tungsten carbide.

The brass we recommend is 99.995% pure and is comprised of approximately 70% copper and 30% zinc.

 

Copper Electrodes

Copper tubing can be used for small hole drilling in all material types. Because of its molecular composition, copper tends to last longer during hole burning compared to brass.

One unique characteristic of copper is its ability to drill through very hard materials such as carbide and tungsten carbide. This is because it has a slower and steadier burn rate that results in a low wear rate. When EDM small hole drilling with a depth to width ratio of greater than 100 to 1 this also tends to be ideal because a lower amount of tapering will leave a more accurate and straighter hole.

The copper tubing that we recommend is 99.995% pure.

 

Tungsten Carbide Electrodes

Where even copper comes up short, tungsten carbide picks up the slack. An incredibly rigid and tough material, tungsten carbide’s singularly low wear rate allows it to cut through exotic materials. Its toughness also frees it from many of the dimensional restrictions placed upon brass and copper tubes. A defect free and stable electrode can be made with tungsten carbide to half the size of the smallest brass or copper electrodes.

This toughness, however, comes at a price. Such a robust material is expensive to work with, and tungsten carbide electrodes are correspondingly more expensive. This makes tungsten carbide more of a rarity, but in its limited applications, it shines.

Tungsten carbide electrodes are made with 6% cobalt.

 

Copper-Tungsten Electrodes

Copper-tungsten occupies the niche between copper and tungsten carbide electrodes. Copper-tungsten electrodes are manufactured by infiltrating a tungsten matrix with molten copper, and the resulting material combines the characteristic of both. Its ability to drill through tough materials is intermediate between copper and tungsten carbide, and like tunsten carbide, it can be manufactured in smaller diameters than brass and copper electrodes.

What makes copper-tungsten truly unique is its availability in foil form. Copper-tungsten is a very machinable material, due to the softness of copper, and sheets of copper-tungsten are perfect for shaping into odd shapes for specialized machining jobs. Copper-tungsten foil is especially useful in stress testing.

 

Silver-Tungsten Electrodes

Silver-tungsten is a true specialist. Similar to copper-tungsten in its manufacture, silver-tungsten is metal matrix composite created by infitrating a tungsten matrix with molten silver. The characteristic that sets silver-tungsten electrodes apart is conductivity. Pure silver is too soft for practical use, but the robustness of a tungsten matrix solves this problem.

The conductivity of silver-tungsten results in holes with a very smooth surface finish. This is very important when holes with well-defined corners need to be drilled.

 

Single Hole Electrode Tubes vs. Multi-Channel Electrode Tubes

Another variable which ultimately determines successful EDM hole burning through a material or work piece is whether the brass electrode or copper electrode tube is has a single hole or multiple channels running directly through the ID or (Internal Diameter) of the electrode.

Basically, an electrode’s intended performance depends on the type of hole going through the center of the electrode, as different channel types are made for different purposes. One purpose is to direct water or coolant through the center of the electrode. This keeps the entire length of the brass or copper tube from overheating and burning up. If the electrode heats up too much it can soften and warp, thus preventing a straight drill or a consistent and accurate EDM hole.

The main factor that determines whether an EDM electrode tube would be single or multi-channel tube is whether the hole to be drilled is a through-hole or a blind hole. Blind holes are not drilled all the way through a workpiece, which leaves a slug or a nipple—a piece of material is still left untouched at the bottom of the hole.

Single Hole (Single Channel) EDM Tubes

Brass EDM tubing and copper EDM tubing can both be single hole. Single hole electrodes are usually cheaper in price because there is less material in the electrode. Single hole tubing is recommended only for hole burning applications that require a hole to be drilled entirely through the part.

If you have further questions or would like clarification in regards to your machine, application or electrode type please email us or call us for further questions. We would be happy to help you and would appreciate any feedback you have to offer.

Multi-Channel EDM Tubes

Multi-channel tubes are used for drilling a blind hole. The internal channels are designed to burn away any material left at the bottom of the hole, as the electrode has material inside the flushing hole that is used to disintegrate the work piece material.

The internal channels are arranged in such a way that, as the electrode spins, no part of the workpiece is left unaffected by the electrode, and no slug or piece of material is left at the bottom of the hole.

 

Do you want to expand Your Hole making Capabilities?


In need of producing Smaller, Deeper, More Precise Holes?

HIGH-SPEED EDM DRILLING

Demand for smaller, deeper and more precise holes produced as fast and as consistently as possible has created a need for more advanced, new Electrical Discharge Machine (EDM) drilling technology in hole making operations. Here are some tips on how to select the EDM drilling system that will help your shop achieve these holes making goals.

  1. Look for an EDM system that is fast, reliable and simple to operate. It should have enhanced drilling capabilities for extremely small hole sizes, but at the same time maintain good surface finish quality and accuracy at greater depths. Considering some of to-day’s applications, it’s important to look for a system that can drill a 15-mm deep hole as small as 0,20 mm in diameter in hardened steel and at the same moment to be able to drill a cooling hole of 2,5 mm in diameter 250-mm deep in mould steel, and this with minute variations in size and straightness from its entrance to exit.
  2. Most experts recommend selecting an EDM drilling system that utilizes the latest in digital generator technology. Digital generator technology, gives EDM drilling machines more precise spark control. It is this functionality that also helps reduce electrode wear. For optimal productivity, the goal is to generate as many holes as possible or drill as deep as required using the least quantity of electrodes. Thus, the more a generator can help reduce electrode wear the better. Plus, less wear on electrodes allows them to cut faster and more accurately by eliminating the “bullet nosing” of their electrode tips.
  3. Seek out an EDM drilling system that can be operated by any person in the workshop, without any high-level programming skills. Simplicity is here the rule.
  4. High-quality surface finish capability is a must. A growing amount of shops now use EDM drilling machines for generating finished holes that will not require any secondary finishing operations.
  5. Keep in mind that uneven wear increases a drilling electrode’s tendency to “walk” off centre, resulting in crooked and angled holes instead of straight ones. Because they help reduce wear, Supper high pressure coolant/flushing system thus prevent such a scenario and contribute to producing straighter holes and ones that can be held closer to size from top to bottom. For instance, a 200 mm-deep hole drilled with a 1 mm electrode on a digital generator-equipped EDM system will vary in size from top to bottom, usually less than 0,025 mm.
  6. Find an EDM drilling system that provides control over heat-affected zones for generating surface finishes comparable to those typically attained using a wire-type EDM. Such surface finishes are possible only with a super high pressure coolant/flushing system with sufficient debit to take the heat immediately away from the working zone.

Conclusion

Today’s technically advanced EDM drilling systems essentially put hole making accuracy in the technological hands of the machine tool. Modern EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality surface finishes.

Check out our perfect and affordable solution : novidrill 400-II new model with granite table, super high pressure coolant pump.

 

http://www.novickedm.com/products/?categ1=High%20Speed%20Drill%20EDM&categ2=Small%20Holes&id=29&language=en

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